Production Line Quality Control Checklist

Receiving clerk pulls the supplier's Certificate of Conformance and matches lot / heat numbers on the material tag against the packing slip and PO. Capture the lot number in the WMS receiving record so traceability follows the material into WIP.

Confirm grade, temper, gauge, and dimension call-outs match the engineering drawing rev currently released in PLM. Substitution by the mill is a common gotcha — the C of C may list an equivalent grade that the customer drawing does not allow.

Visually inspect for handling damage, surface corrosion, and contamination. For adhesives, resins, and any time-dated material, confirm the lot is within shelf life and that storage conditions on the C of C have been met during transit.

Use the XRF / OES gun to verify alloy on stainless, Inconel, and any pressure-rated stock before release to the floor. Wrong alloy mixed into a pressure part is the kind of mistake that causes field failures — positive material identification is non-negotiable on alloy-critical materials.

Pull the sample size dictated by the AQL plan for this material category — typically Level II Normal inspection. Measure critical dimensions on the sample with calibrated gauges and record results on the incoming inspection sheet.

Tag the lot with a red hold tag and move it to the MRB cage. Open the NCR in the QMS with the supplier name, lot, defect, and a photo. The buyer notifies the supplier the same day so the supplier can begin a containment response and replacement shipment.

Cross-check the routing rev on the traveler against the current released rev in PLM. Pending ECNs that affect this part must be resolved before setup — running the prior rev after an ECN release is a frequent scrap event.

Pull the gauges called out on the inspection sheet from the gauge crib and check each calibration sticker. Past-due gauges are red-tagged and replaced before setup begins. Also verify tool inserts and fixtures match the setup sheet — wrong insert is a common scrap-on-first-piece cause.

Setup operator loads the program (CNC) or recipe (process), seats the fixture, and zeros the work offsets. Setup-reduction (SMED) goal for this work center is documented on the setup sheet — flag any setup running over target so the cell lead can investigate.

Quality runs the first piece across every characteristic on the ballooned drawing. CMM is required for any GD&T callout. Do not release-to-run until FAI is signed by Quality — running 200 parts before discovering a setup error is the canonical reason changeovers go sideways.

If FAI failed, adjust offsets, re-zero, or swap tooling per the deviation pattern. Re-run the first piece and re-submit for FAI. Document each correction attempt on the traveler so the manufacturing engineer can review setup capability later.

Operator records pieces produced and any downtime against standard reason codes (changeover, breakdown, material wait, quality hold). This data feeds OEE and the morning Gemba review — codes left blank distort availability and performance.

Pull the in-process sample at the frequency on the control plan (typically every Nth piece or every hour). Measure variable characteristics with the calibrated gauge specified for that feature; record on the SPC sheet or directly into InfinityQS / Minitab.

Plot the new subgroup and check Western Electric / Nelson rules — points out of control limits, runs of seven, trends. Out-of-control conditions trigger the reaction plan on the control plan, which usually means andon and supervisor review before continuing the run.

Supervisor or quality engineer performs a layered process audit (LPA) at the cell. Confirm the operator is following the current rev of the work instruction, that PPE is correct, and that poka-yoke devices are in place and functioning.

Quality inspector pulls the AQL sample (ANSI Z1.4, Level II Normal unless customer specifies otherwise) from the completed lot. Measure critical-to-quality dimensions and inspect cosmetic features against the boundary samples. Reject the lot if defectives exceed the acceptance number.

Confirm packaging configuration matches the customer's packing instruction — count per carton, dunnage, desiccant, ESD bag where applicable. Verify the lot code on the carton label matches the WO traveler so traceability survives downstream.

Upload photos of the finished part, the carton label, and the palletized configuration. These attachments are the backstop when a customer reports a damage or labeling issue weeks after shipment.

Quality manager reviews the FAI, in-process SPC, final inspection results, and any deviation notes. Disposition the batch as Released, Released with rework, or Rejected. The batch record is the audit-trail artifact for ISO 9001 / IATF 16949 surveillance.

Apply red hold tags and move parts to the MRB area. Un-segregated rejects mixed back into stock is the most common cause of customer escapes — the cage discipline is the control.

Open the NCR in the QMS with quantity, defect description, and root-cause hypothesis. The MRB (engineering, quality, production) dispositions to rework, scrap, use-as-is with deviation, or return-to-supplier. NCRs left open past 30 days escalate to the quality manager.

Enter actual setup time, run time, scrap quantity, and rework quantity against the WO. Variance vs. standard cost is reviewed by the production manager at end-of-shift; persistent variances feed the next kaizen target.

Update the shift log with WO status, partial completions, open NCRs, and any tooling or gauge issues encountered. Walk the incoming shift lead through the cell so in-process WOs continue without restart loss.