QA/QC Forms

Overview

To truly ensure and capture quality at the source, a tool integral to your shop's workflow is critical.  Manufacton provides customizable forms with a comprehensive built-in workflow to ensure quality is met and provide an integrated mitigation process.

This article covers the following:

• Identifying Types of Failures
• Building QA/QC Forms
  • Form Components
• Applying QA/QC Forms to Order Templates
• Using QA/QC Forms
• QA/QC Form Workflow
• Exporting QA/QC Forms
• QA/QC Forms Video

 

Identifying Types of Failures

Prior to creating a QA/QC Form, it is advisable to standardize a list of possible failure types your enterprise wants to capture.  Manufacton comes with three (3) default failure types:

• Engineering Defect
• Manufacturing Defect
• Not to Spec/Out of Tolerance

It is possible to delete, modify and or append these types:

1. Go to App & Project Settings
2. Select Manufacton Settings
3. Select Lists
4. Select Qa/QC Issue Types
5. To add a new Issue Type select Add New ("+")
6. To edit an existing Issue Type select the Edit Pencil
7. To delete an existing Issue Type, select the ellipse and "Delete"

 

Building QA/QC Forms

Administrators create QA/QC Forms in:

1. App & Project Setup
2. Manufacton Settings
3. Templates
4. Selecting QA/QC Forms
5. Selecting the Add New ("+") button
   
   
6. There are four (4) components to a QA/QC Form.
7. Each QA/QC Form requires a unique name and ID.
8. QA/QD Form components are added to the form template by dragging and dropping the desired element onto the form template and configuring each element as needed.
   
   

QA/QC Form Components

All QA/QC Forms can include any of the following elements:

1. QA/QC Support Documentation
   • The overall QA/QC Form can have a reference document associated with it, either an uploaded document or URL link to a cloud-based document is supported
2. QA/QC Notes/Overview element can be added to the top of the QA/QC Form
   
   • This element can contain instructions on how to use the form, etc.
   • This element can only be added once to a QA/QC Form and will always appear at the top.
3. QA/QC Check (Simple) elements can be added to the QA/QC Form.
   • This element is used for quality checks which do not contain a range of acceptable values.
   • This element type can be added as many times as is desired to a QA/QC Form.
4. QA/QC Check (w/Criteria) element can be added to the QA/QC Form.
   • This element is used for quality checks which do contain a range of acceptable values.
   • This element type can be added as many times as is desired to a QA/QC Form.
5. Signature element can be added to the top of the QA/QC Form
   
   • This element enables the person filling out the form to check to sign their name to the form when it is completed.
   • This element can only be added once to a QA/QC Form and will always appear at the bottom.

The Preview Form button in the editor allow you to preview the elements of the form before saving it.  This allows you to ensure the form and form elements are as expected:

Note:  The QA/QC Form's workflow is only enabled when it is in the context of
       a Production Order.  It is not enabled in "Preview" mode.

 

Applying QA/QC Forms to Production Order Templates

QA/QC Forms can be added to any Production Order Template type ("Basic", "Kit" and "Assembly").

The QA/QC Form is added in line with any Work Step (F/K/A "Run") in the Template.

Once a Work Step (Run) is added:

1. Select the Add QA/QC Form ("+") symbol
2. Select the desired QA/QC Form to be completed prior to the Workstep's completion
3. Set Assignee for the QA/QC Form
4. Select Add QA/QC Form

Notes:  o Only one QA/QC Form can be added to each Work Step.  If multiple QA/QC 
          checks are required, additional Work Steps should be added.
        o It is also possible to add QA/QC Forms directly into Production Orders.
          They do not have to be applied via Templates.

 

Using QA/QC Forms

QA/QC forms within Production Orders have a fully integrated workflow.  Work Steps to which the QA/QC Form is applied must be 100% completed and all checks passed before that Work Step can be marked "Complete".

QA/QC Forms that have not been started for a Work Step will show up as empty circles.

Selecting the QA/QC Form from the QA/QC column in the Work Steps sub-tab will open the form.  Here the workflow is enabled for the checks added to the form.  There are several other elements to note:

1. The Overall QA/QC Status of the form
2. Access to the QA/QC Support Document
3. The QA/QC Notes/Overview
4. A summary of the QA/QC Checks and their current status
5. The Checks added to the QA/QC Form
6. The Signature checkbox for when the form is complete
7. The option to Pause the order (see the KB Article on Pausing Orders)
8. The Submit Form button

 

QA/QC Form Workflow

Each check within a QA/QC Form must be passed for the overall QA/QC Form to pass.  And, the QA/QC Form must be passed for the Work Step to which the QA/QC Form is attached can be completed.

Note:  It is also possible to mark a check as "Does not apply" by unchecking the
       checkbox.

       

Passing a Check

If the criteria for the check is met, the check can be marked as Pass:

1. If the check is a QA/QC Check (Simple) type, supporting document (including photographs), and notes on the inspection can be added (optionally).
2. If the is a QA/QC Check (w/Criteria) type, the value of the passing criteria must be entered (optional supporting documents and notes can also be added).

Failing a check

If a check fails during inspection:

1. An Issue Type must be provided
2. An Owner for the follow-up Task must be assigned
3. The Measured Value must be entered (for w/Criteria type checks)
4. A Document may be added
5. Notes may be provided
6. The green check to Save is then selected

Mitigation of a failed check

Once the task to mitigate the failure has been completed, any failed checks can be:

1. Marked Ready for Inspection.
2. The Task can be assigned to a new owner
3. Supporting documents (images) can be attached
4. The check is then saved and is ready for reinspection.

Reinspection of a mitigated check

Once a check has been marked as Ready for inspection, the process is repeated and can be passed or failed again.  All the while, the QA/QC Form is tracking each pass/fail and reinspection.

QA/QC Form Status

Within the order, and within the QA/QC Form, a summary status of the current state of the check(s) is maintained, with indicators for:

1. Overall QA/QC Form Status
   And within the form itself...
2. Passed checks
3. Failed Checks
4. Checks ready for reinspection

Completing QA/QC Forms

Once all of the checks within a QA/QC Form are complete, the QA/QC Form must be:

1. Signed and
2. Submitted
3. Only then, can the Work Step with the QA/QC Form be marked as Done

 

Exporting QA/QC Forms

Once QA/QC forms are filled out, it is possible to export all the forms from an order and have those forms emailed to you.

To export the forms within a production order:

1. On the WORK STEPS sub-tab, select “Export Order QA/QC Forms” from the Bulk Actions drop down menu.
2. Select the QA/QC forms you want exported
3. Select whether to “Generate a separate PDF for each Work Step
4. Select Export Forms
   • A zip file with PDF(s) of the desired form(s) will then be emailed to you

The PDF will contain the following elements:

1. The Company Logo (as defined in App & Project Settings è Company Profile è Account)
2. The Name of the QA/QC Form
3. The Status of the QA/QC Form
4. Company, Project, Order and Work Step information
5. Any Documents and/or Photos will have links to the source file.  A thumbnail of the photo is also provided.
6. Each QA/QC check will have the full status of all the criteria, status, note, data on who/when the check was performed and links to any documents and photos (thumbnails of photos are provided).

 

QA/QC Form Video

For a brief (~9 min) video on everything you need to know about QA/QC Forms please take a look at this video: