Quality Control System

 

Quality Control System

Overview

The Quality Control enhancement is designed to address Quality Control aspects of a Quality Management system.  The enhancement will provide xTuple with tools for creating Quality Control Specifications and Plans, assigning them to items, and applying them as a part of business process transactions, such as receiving and shipping, and manufacturing production. The enhancement will also provide tools for collecting quality control test results which can ultimately be used in reporting and analysis.

The Quality Control system will be delivered by xTuple's Mobile Web framework and initially will not be available on the Qt Desktop client.  Quality Control will be an extension of the Manufacturing and Shop Floor functionality.

Terminology

Quality Test Specification -  A document used to define a structured Quality Test specification.  The test specification is a definition of what each test entails, including the test type, the target value, and tolerance limits.  Detailed test instructions are recorded on this document.  The test specification is (potentially) item independent and can be reused across multiple items as defined on the Test Plan.  Possible inclusion in the specification is the test equipment that will be utilized.

Quality Test Plan - The Test Plan defines a specific test regime and will include one or more test specifications.  Assignment to an Item Site is defined here - a Test Plan can be re-used across multiple items.  Test frequency is also defined on the Test Plan and is used to determine when a Test document is created.  For example - frequency might include first item testing, last item testing, or full testing (of each item).  The Test Plan defines at what trigger point in a business process, a test is initiated.  For example, Post Operation, Post Production, Ship Item, Receive Item.  The Test Plan holds the revision version and status for change control purposes.  The Test Plan also holds the workflow definitions that determine disposition activities required upon events such as a test failing. 

Quality Test Document -  The Quality Test document is generated based on the Test Plan requirements - this document reflects the actual testing process.  So a Test will be created and assigned based on business workflow trigger points - such as Post Operations, Post Production, Goods Receipt, Ship Shipment.  The Test Documents holds details about the Test Specification, the Item, the Lot/Serial Number, and the overall status of Test Items.  The Test will also hold the overall disposition of the test and associated item.  The Test holds the specific instance of workflow generated from the Test Plan for this particular test document.

Test Items - The test items reflect the test specifications off the test plan that generated the test document  These items hold information about the test to be conducted and enable recording of actual test results.  Each test item can have an independent pass/fail status which will also influence the overall Test status.

Disposition - If a test fails (the item does not meet defined specifications) then several actions can occur depending on business requirements.  Activities such as scrapping, rework, quarantine can occur.  Tied in with this notifications to appropriate persons will also occur.

Workflow - The new workflow system in xTuple Mobile Web enables powerful and flexible activities to occur depending on the business requirements.  The workflow system will be utilized to managed failed items that fail tests, notify relevant persons, and to dynamically control the events in the Quality system.

Details

Quality Specifications will define specific tests that must be completed at different points where quality will be measured. These questions may be of the true/false type, numeric, or text (subjective test comments).  Specifications will be used to define detailed test instructions which will be carried through to the Test Document.

The Quality Control system will allow users to create Quality Plans, which are made up of Quality Test Plan Items (Specifications).  Quality Plans will track revisions; as Quality Specifications are added, removed or changed, the Quality Plan revision number will be incremented. Quality Tests documents will also record the version of the Test Plan used.

Test Plans may be assigned to key transactions. So, for example, a Test Plan can be created for a purchased item and assigned to the goods receiving transaction. When that item is received from the vendor, the Quality Test Document screen will launch, allowing the user to inspect the received items and record quality information.

Test Plans may also be assigned to specific Operations and also to the Post Production step for manufactured items. If quality control tests are required as part of the manufacturing process, they will need to be defined as specific Operations.  When production is posted, the system will prompt the user to inspect items and record quality information. Processing of an item will not be able to proceed until the Quality Test Document has been passed.

Test documents will be generated automatically based on business trigger points.  These documents are used to record the test result or results of multiple tests.  You will be able to assign test items to different users.  The actual test result can be entered and will trigger a status update of the Test as well as pre-defined workflow activities to be generated. The activities are used to notify the relevant person that a test has failed and they are required to undertake disposition actions.

Purchased and manufactured items that fail inspection/testing will be handled with various disposition assignments.  The system will allow the administrator to define disposition actions based on workflow activities.  Defined dispositions will initially include Scrap, Rework, Quarantine (and Release - if nothing is required to be done).

The system will include report screens to view inspection results by item, by lot/serial, by product category, by vendor, by date range, by user (inspector).

New tables

Quality Specification

Quality Test Plan

Quality Test Plan Item (Test Plan)

Assign Spec to Item

Quality Test Document

Quality Test Item (Test results)

Workflow

 

Reporting considerations:

For numeric tests the actual test result will be able to be entered.   The recording of a test result will trigger a pass/fail status of the test based on tolerances on the Test Plan.  From the recording of actual results various items of reporting will be possible

  • Test Document - a printable test document allowing test items and their instructions to be generated and actual results recorded.
  • Test Results - a list of completed tests and their relative test statuses
  • Non-Conformance document.  This will likely be required to be customised by the organisation.
  • Test Certificate - a basic document will be enabled as it is expected the actual business requirement will be very specific and require customisation.

Dependencies:

The Quality Control extension will be built as part of the Manufacturing extension so will rely on delivery of certain key elements of xTuple functionality.  The QC module will be dependent on manufacturing, and inventory especially in the areas of Post Production, Post Operations, Goods Receipt, Ship Shipment.  Furthermore disposition activities may be required to tie in with manufacturing and inventory activities - such as revering post production/operation, and scrap.

Questions:

1. Will the system need to record lot/serial numbers for inspected items?   Answer: Most likely lot/serial tracking will be required.

2. Will the system need to run Quality Test Plans at specific operations during the manufacturing process, or will inspection occur only at the Post Production step?  Answer: Most likely specific Operations will be set up for QA testing.  Post Production cannot occur until the testing has passed - or production will be posted but the item(s) quarantined in inventory.

 

 
nclaytor's picture
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Joined: 03/31/2009
Initial comments on the spec
Must be able to support ISO9000 for our purposes, probably FDA compliance for others

Inspection of incoming items upon move from QA site type to normal site type

Inspection of more than one, but not all, items in a lot
SPC data input for a lot?
Ability to display/print PDFs is becoming more crucial all the time. There is a free, open source, cross-platform PDF library that could be used for this.
Yes to both questions (collect lot/serial data on inspected items, inspect at times other than post production)
 
I agree that the desired reporting will drive a lot of the spec for functionality. In that vein, the graphical reporting in xTuple (at least 3.8) is extremely weak, and should be updated to support this effort. I am currently using Excel with VBA sending queries for any sort of time-series reporting, and it is really clumsy to use.
 
jremillard's picture
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Joined: 12/19/2013
QMS

Can someone please provide an update on what the status on this is?

 

Thanks,

Jason

 
shackbarth's picture
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Joined: 06/28/2012
Status

We're hard at work implementing this, and I'm hoping that we'll be done by the end of the year. Note of course that you'll need to have access to our new technology--the xTuple Server, specifically--to take advantage of it.

 
ned
ned's picture
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Joined: 10/20/2008
We'll be previewing it in

We'll be previewing it in October at our xTupleCon user conference.  Join us!