Finished Goods Quality Assurance Checklist

Cross-check the WO number, part number, and rev printed on the traveler against the ERP / MES record. Mismatches at this step usually trace to an open ECN that wasn't cascaded — stop and verify with manufacturing engineering before sampling.

Use the sampling plan referenced on the control plan (typically Z1.4 General Inspection Level II, AQL 1.0 for major / 2.5 for minor). Pull randomly across the lot — front, middle, end of run — not just from the top of the tote.

Check for scratches, dents, burrs, flash, weld spatter, contamination, missing or illegible labels, and incorrect part-number/rev markings. Record defect counts by category against the AQL accept/reject numbers — don't accept the lot just because no single defect type exceeded its limit.

Pull the master and limit boundary samples from the QA cabinet; compare under the lightbox at the standard angle. Boundary samples expire — confirm the cal sticker is current before relying on them.

Open the NCR in the QMS with photos and defect counts, red-tag the totes, and move the lot to the segregation cage. Do not adjust the WO quantity until MRB dispositions (use-as-is, rework, scrap, return-to-supplier).

Confirm each micrometer, caliper, and pin gauge has a current calibration sticker. Past-due gauges get red-tagged and returned to the cal lab; do not use them on a release inspection.

Measure every dimension flagged Critical-to-Quality on the print and every characteristic called out on the customer's control plan. Record actuals — not just pass/fail — so SPC trends stay alive.

Bracket the run with a CMM check on the first and last piece off the machine. A drift between the two is the early signal of tool wear or fixture movement that an in-process gauge can miss.

For variable characteristics under SPC, calculate Cpk for the run and compare to the control plan minimum (commonly 1.33 for ongoing, 1.67 for PPAP launches). If Cpk has slipped from prior runs, raise it with the process engineer before next release.

Run the EOL test fixture per the test spec; capture the test report by serial number. Confirm the fixture self-check (gold sample) passed at shift start — a fixture drift will pass bad parts and fail good ones.

Performance limits in the customer drawing notes often differ from internal thresholds — usually tighter. Verify the spec actually being applied is the customer's, not the supplier's default.

Run the safety-related test called out on the control plan (dielectric withstand, ground bond, leak rate, pressure decay). These are 100% tests on most regulated products — sample inspection is not a substitute.

Trip each interlock by hand and confirm the unit shuts down within the spec time. A guard sensor that reads OK statically can still fail dynamically — exercise it.

Red-tag the failed units, record serial numbers in the NCR, and stage in the MRB cage for review. Do not allow rework on the line without a documented disposition — undocumented rework is a frequent ISO 9001 audit finding.

Tie each serial to its WO, machine, operator, and shift in the MES. Serial gaps or duplicate entries break downstream recall queries — fix them at this step, not at audit time.

Match the heat / mill-cert numbers from the raw material receiver to the WO. Aerospace and pressure-vessel work requires single-heat lots; mixed heats need an explicit waiver from the customer.

The Certificate of Conformance and Certificate of Analysis carry the quality manager's signature and the lot's traceability data. Use the controlled template — handwritten certs fail customer receiving inspection.

For automotive customers under IATF 16949, confirm the PPAP level (1–5) called out on the customer requirements still covers this run. A process change since last PPAP triggers re-submission before release.

Verify carton size, dunnage, count per carton, and stack pattern against the customer's packaging spec. Generic boxes substituted for customer-specified returnable totes are a common chargeback.

For electronics or moisture-sensitive components, seal in MBB with desiccant and an HIC; mark the MSL level per IPC/JEDEC J-STD-033. ESD-sensitive parts go in pink poly with an ESD warning label.

Scan each carton label to confirm the barcode resolves to the correct part / qty / lot. Country-of-origin marking and any fragile / this-side-up icons must match the BOL — labeling mismatches stop the truck at the customer dock.

Move released stock to the bonded FG location in the WMS — never staged loose on the floor. Released and unreleased stock sharing a rack is the most common cause of unintended shipment of held inventory.