Inspections Guide
Incoming, in-process, and final inspections.
Overview
The Inspections module allows you to record and track quality inspections at various stages of your process.
Key Features
- Multiple Inspection Types: Incoming, in-process, final, and source inspections
- AQL Sampling: Automatic sample size calculation per ANSI/ASQ Z1.4
- SPC Integration: Collect data for statistical process control
- NCR Generation: Create NCRs directly from failed inspections
- Supplier Tracking: Inspections linked to supplier performance
- Document Attachments: Upload inspection reports and photos
Inspection Types
Incoming Inspection
When: Receipt of purchased materials
Purpose:
- Verify supplier quality
- Check against purchase order
- Identify issues before production
- Support supplier scorecards
In-Process Inspection
When: During manufacturing
Purpose:
- Monitor process stability
- Catch issues early
- Collect SPC data
- Verify work instructions
Final Inspection
When: Before shipment
Purpose:
- Verify product meets specifications
- Authorize release to customer
- Generate quality certificates
- Complete traceability records
Source Inspection
When: At supplier location
Purpose:
- High-value or critical items
- Verify before shipping
- First article inspections
- Process capability verification
Creating an Inspection
Step-by-Step Guide
Step 1: Navigate to Inspections
Click Inspections in the sidebar, then + New Inspection
Step 2: Select Inspection Type
Choose Incoming, In-Process, Final, or Source inspection
Step 3: Enter Basic Information
- Supplier: (for incoming/source)
- Part Number: Product being inspected
- Lot/Batch: Lot number for traceability
- Quantity Received: Total quantity in lot
- PO Number: Purchase order reference
Step 4: Define Sample Plan
Enter sample size manually or use AQL calculator to determine appropriate sample size.
Step 5: Record Results
For each characteristic:
- Enter measured values or pass/fail
- Note any defects found
- Upload photos if applicable
Step 6: Complete Inspection
Mark as Accepted, Rejected, or Conditional. Failed inspections prompt NCR creation.
AQL Sampling
AQL (Acceptable Quality Level) sampling determines how many units to inspect from a lot based on statistical methods.
How AQL Works
- Lot Size: Total quantity received
- Inspection Level: General (I, II, III) or Special (S-1 to S-4)
- AQL Value: Maximum acceptable defect percentage (e.g., 1.0%, 2.5%)
- Sample Size: Calculated from ANSI/ASQ Z1.4 tables
- Accept/Reject: Based on defects found vs. acceptance number
Common AQL Values
| AQL | Typical Use |
|---|---|
| 0.065 - 0.15 | Critical defects (safety-related) |
| 0.25 - 1.0 | Major defects (function-affecting) |
| 1.5 - 4.0 | Minor defects (cosmetic) |
SPC Integration
Inspection data can be fed into SPC (Statistical Process Control) charts for trend analysis and process monitoring.
Available Chart Types
Variables Data (Measurements)
- X-bar & R: Average and range charts
- X-bar & S: Average and standard deviation
- Individual & MR: Individual values and moving range
Attributes Data (Pass/Fail)
- p-chart: Proportion defective
- np-chart: Number defective
- c-chart: Defects per unit
- u-chart: Defects per unit (variable sample)
Process Capability
- Cp: Process capability (spread vs. specification)
- Cpk: Process capability considering centering
- Pp/Ppk: Process performance (overall variation)
Inspection Workflow
Inspection Status Flow
Awaiting inspection
Being inspected
Passed
Failed → NCR
Disposition Options
- Accepted: Release to stock/production
- Conditional: Accept with deviation approval
- Rejected: Return to supplier, rework, or scrap
- On Hold: Pending further review