Quality Control - [Survey]

Quality Control Module – Introduction Plan

• The Quality Control (QC) Module ensures that materials and finished goods meet predefined quality standards at every critical stock movement.
• The system automatically triggers quality checks during incoming, in-process, and outgoing transactions.
• Each quality check uses predefined test cases per item, validates results against min–max limits, generates a unique reel number, and determines pass or fail status.
• QC reports provide full traceability and support quality monitoring and improvement.

Module Structure

Transactions	Masters	Reports
QC Entry	Quality Parameter Master	QC Inspection Report
	Test Plan Master	Item-wise & Machine-wise QC Report
	Test Plan Parameter Mapping	Transaction-wise QC & Pass vs Fail Summary Report

Masters

Quality Parameter Master

• Stores reusable, atomic quality checks (measurements or observations) such as voltage, dimensions, or visual conditions with validation rules.
• Example

  parameter_code	parameter_name	parameter_type	min_value	max_value	is_active
  000001	Input Voltage	NUMERIC	220	240	Y
  000002	Power ON Test	PASS_FAIL	PASS	PASS	Y
  000003	Housing Damage	PASS_FAIL	PASS	PASS	Y
  000004	Earth Continuity	PASS_FAIL	PASS	PASS	Y
  000005	Current Leakage	NUMERIC	0	0.5	Y
  000006	Label Correctness	PASS_FAIL	PASS	PASS	Y

Test Plan Master

• Defines a quality inspection checklist for a specific QC stage (IQC/IPQC/FQC), including sampling rules and execution behavior.
• Example

  test_plan_code	test_plan_name	qc_stage	item_group_code	is_active
  000001	Floodlight IQC	IQC	001	Y
  000002	Floodlight FQC	FQC	001	Y
  000011	Streetlight IQC	IQC	011	Y
  000012	Streetlight FQC	FQC	011	Y

Test Plan Parameter Mapping (Line Level for Test Plan Mst)

• Links Quality Parameters to a Test Plan and defines the execution order and plan-specific limits for each parameter. We can take this as line of Test Plan
• Example

  test_plan_code	parameter_code
  000001	000003
  000001	000001
  000001	000004
  000001	000002

Transactions

QC Entry

Main Level (QC_Entry)

• Represents a single quality inspection transaction created against a business document such as GRN, production, or dispatch.
• Example

  qc_doc_no	qc_type	ref_doc	ref_no	ref_date	mode	status
  000001	Incoming	GRN	450123	2026-01-10	System	OPEN

Line Level (QC_Entry_1)

• Captures report number, date, remarks, itemid and docid
• Example

  qc_doc_no	item_id	report_no	report_date	status	doc1_id
  000001	500101	RPT123	2026-01-10	PASS	991
  000001	500102	RPT124	2026-01-10	FAIL	992

Line Level (QC_Entry_2)

• Records will be inserted only when Mode is System
• Captures individual parameter results, measured values, and pass/fail status for a specific QC inspection.
• Example

  qc_doc_no	doc1_id	parameter_code	actual_value	result
  000001	991	000001	230	PASS
  000001	991	000002	PASS	PASS
  000001	992	000004	FAIL	FAIL
  000001	992	000001	236	PASS

Reports

QC Inspection Report

• Shows complete inspection details for a single QC transaction.

Item-wise QC Report

• Shows QC performance history of each item.

Transaction-wise QC

• QC linked to GRN, Job Work, MIRS, Sales Return
• Shows QC status linked to business documents.

Pass vs Fail Summary Report

• High-level quality health snapshot.

Parameter Fail Report

• Shows which parameters fail most often.

Item Group Mst Change

• We will add a column Test Plan Id. To Link Test plan and Item Group

QC Entry (Transaction Overview)

QC Entry is the main transaction used to record and validate quality inspection results against business documents.

Key Points

• QC Entry is created by selecting:

1. Document Type (GRN, Jobwork, Production, Invoice, etc.)
2. QC Type (Incoming / Production / Outgoing)
3. Reference No & Reference Date
4. System automatically fetches eligible item lines from the selected document.
5. QC is performed item-wise for all fetched lines.
6. Each QC Entry is assigned a unique system-generated number.

QC Execution

• QC can be performed in:

1. Manual Mode (QC report number, date, status and upload and validation)

• The uploaded document will be validated.

2. System Mode (parameter-based inspection through system)

• Each item is marked as PASS / FAIL / HOLD based on QC results.

Control Logic

• Items marked PASS are allowed for next business actions (stock, production, dispatch).
• Items marked FAIL / HOLD are blocked.

QC Standalone Module

• For Document instead of selecting GRN / Invoice / MIRS User selects Reference Type = EXTERNAL and Reference No = Vendor Lot / Batch / Manual No
  QC Type : Incoming
  Ref Doc : EXTERNAL
  Ref No : LOT-AL-240912
• If no ERP document exists that is QC is external then user can manually add items.

Other Points

• We can introduce Lot Qty and Sample Qty in QC Entry Line.
• The inspector has to fill the worst case value from the sample for QC inspection.
• Inspector Name also needs to be introduced.