Order Fulfillment Checklist

Match the PO line items, part numbers, and unit prices to the active quote or blanket release. Watch for stale revisions on long-running blanket POs — buyers often re-issue against an old quote that predates an ECN.

Confirm the ship-to is current (customers move docks more often than they update vendors) and that Incoterms — FOB Origin, FOB Destination, EXW, DDP — match the contract. Mismatched Incoterms create freight and duty disputes after the fact.

Run availability against the BOM in ERP. For partial coverage, flag long-lead components (castings, custom hardware, electronics) and confirm PO status with the buyer before scheduling.

Pull the controlled drawing from PLM (SolidWorks PDM, Arena, Windchill). Verify the rev on the customer PO matches the rev on the routing. If an ECN is in flight, hold release until the ECN is approved and operator training is delivered.

Slot the work order into the MES schedule at the constraint work center. Avoid stacking the bottleneck cell — drum-buffer-rope means non-CCR cells absorb the variance.

Material handler pulls per the staged kit list and stages at the work center. Verify shelf-life dates on adhesives, resins, and paint; expired stock is a common scrap driver.

Record lot, heat, and certification numbers on the traveler. Required for AS9100, IATF 16949, ISO 13485, and any customer with PPAP. Missing traceability blocks shipment release at final QC.

Pull tooling from the crib per the setup sheet. Confirm punch / die / fixture condition; red-tag worn tooling rather than running it. Setup time variance traces back to tool condition more often than to operator skill.

Check the calibration sticker on every gauge used for FAI — calipers, micrometers, pin gauges, height gauges. Past-due gauges are red-tagged and pulled from service. A 0.0003" gauge drift can sink an entire production lot.

Setup operator follows the standardized work for the work center — load program, set offsets, verify zero. SMED targets here: setup is non-value-added time, every minute counts at the constraint.

Quality measures every critical and major characteristic on the first piece against the inspection sheet. Aerospace work follows AS9102; automotive follows the customer's PPAP control plan. Do not release to run until FAI is signed off.

Document the failing dimensions on the NCR, segregate the first piece, and adjust offsets or fixture. Re-run FAI before any further parts are produced. Do not consume run-time material to debug a setup.

Sample per ANSI Z1.4 at the cadence on the control plan — typically every Nth piece or every hour. Trend the variable data on an X-bar R chart; pull the andon if the process drifts beyond the control limits.

Operator logs good count, scrap count, and downtime reason codes hourly into MES (Plex, Tulip, MachineMetrics). Drives OEE and supports end-of-run variance review.

Quality samples the lot against the AQL plan and signs the inspection sheet. Verify lot traceability paperwork is complete before disposition; missing certs block customer release.

Quality manager opens an NCR, segregates the lot to the red-tag area, and selects disposition: rework, use-as-is with customer deviation, scrap, or return-to-supplier. Do not leave parts unsegregated overnight — mix-ups become recall events.

Shipping clerk confirms part number, quantity, and lot per pick list. Customer-specific packaging (KLT bins, returnable dunnage, ESD bags) is set in the routing — substituting standard cartons creates chargebacks.

Apply customer-required labels (AIAG B-10 barcode, Odette, Mil-Std-129 for defense). For hazmat, apply UN markings and DOT labels per 49 CFR 172. Wrong UN number or packing group is a common carrier-refusal cause.

Generate the BOL, packing slip, and any required certs — material certs, certificate of conformance, FAIR for aerospace. Capture the carrier's PRO or tracking number on the work order before pickup.

Production supervisor confirms actuals are entered — setup time, run time, scrap, rework — and closes the WO. Variance review at end-of-shift catches labor and material drift before it compounds across the week.