How do I check the quality of every production stage without papers lost between departments?
| Intagya ERP
Tie the check to the operation itself, not to paper. In Intagya ERP you add the Quality Control app and find the factory stages ready, with their items, method and acceptance rule. When a receipt, a manufacturing order or a delivery is confirmed, a sheet opens for each stage the product goes through. The inspector marks each item accepted or failed, each role owner signs for himself, and the order stays open until the sheet is validated when you ask for that.
The factory manager walks into assembly and asks for the cutting inspection sheet of the wardrobe batch. The supervisor checks the drawer, then the notice board, then says: I think the quality controller took it to the office. It is there, empty except for one signature.
The wardrobes have been at the customer for two days.
Why does a printed inspection sheet fail?
Because it sits apart from the work. The manufacturing order moves in the system, the sheet moves in someone's hand. If that person is late or forgets, the order moves on as if the check happened.
Even when the sheets are filled in every time, they end up in a folder nobody reads. You cannot tell which item fails most this month, or which stage runs late, unless someone gathers the sheets by hand.
In my view the inspector is not the problem. The problem is that the check is optional as far as the system is concerned. Make it part of the operation, so the order cannot move without it.
How does the sheet open by itself with the manufacturing order?
In Intagya ERP you add the Quality Control app from Add an app; it is suggested to everyone who uses Manufacturing. It comes with ready stages for furniture factories: receiving materials, cutting, edge banding, assembly, painting, packaging and more. Each stage has its items, and each item has a method, an acceptance rule and a frequency.
When the planner confirms a manufacturing order, a sheet opens for each manufacturing stage. A receipt opens the raw material sheet, and a delivery opens the packaging and pre-shipment sheets. Nobody prints anything.
The inspector opens the sheet on a computer or a tablet and presses Accepted, Failed or Not applicable for each item. When an item fails, he writes why in the notes. The ring at the top tells him how many are left.
Does every product get every stage?
No, and this matters. A wooden dining table does not go through upholstery, and a sofa does not go through glass cutting. If the system opened every stage for every order, the list would fill with sheets that mean nothing, and people would stop opening them.
So you link each stage to the product categories that go through it. Glass cutting for glass tables, upholstery for sofas and upholstered chairs. A stage with no categories covers every product, like cutting and packaging.
Link only the special stages first, such as glass, upholstery and lighting, and leave the general ones for every product. Then confirm one manufacturing order for each kind of product and check its sheets.
How do I stop a product leaving before it is checked?
Each stage has a Block validation switch. When it is on, the receipt or delivery is not validated and the manufacturing order is not closed until its sheet is validated. The user sees why, and does not need to ask anyone.
Validation has clear rules too. Every item needs a result, and the product status must be chosen: Accepted, Rework or Rejected. When a single item failed, Accepted cannot be chosen. From the failed items you open a quality alert in one click, with a team, a root cause and a corrective action.
Who signs the sheet?
On paper anyone could write a name in the Department Head box. Here each role has its own users or group. The production supervisor signs his role, the quality controller signs hers, and nobody sees the Sign button on a role that is not theirs.
If someone tries to sign for another person, the system refuses and names who signs. Nobody types the signer's name; it is recorded with the date.
How do I see where quality is slipping?
The Overview page answers without anyone gathering sheets. The acceptance rate of the month with a bar for each week, the waiting inspections with those blocking an order first, the items that fail most, and what waits for your signature with a Sign button.
If Edge tape peels at the corners tops the list three weeks running, the cause is most likely glue temperature or machine speed, not the worker. That is something a single sheet never tells you.
Tomorrow morning: open Stages and Products, link three special stages to their categories, and choose who signs the quality controller role. Then confirm one manufacturing order and inspect its sheets yourself before you ask the team to.
FAQ
Can I change the ready stages and items?
Yes. You rename stages and items, change the method and the acceptance rule, add your own stages and items, and switch off what you do not need.
What if I do not choose who signs a role?
A quality manager signs it. Once you choose users or a group for the role, nobody else signs it.
Does the app work without Manufacturing?
It needs Manufacturing and Inventory, because sheets open with manufacturing orders, receipts and deliveries.
Can I print an inspection sheet?
Yes, each sheet has a PDF report with the items, results and signatures.
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