Quality Checklist
Execute inspections on the shop floor — enter measurements characteristic by characteristic and get an automatic accept or reject decision for the entire lot.
Overview
A Quality Checklist is a live instance of an Inspection Plan. When an inspector starts a new checklist, TotalApp copies the plan's characteristics, sampling limits, and defect thresholds into a working record tied to a specific lot number. The inspector enters measured values or pass/fail results one characteristic at a time, and submits when done. The system then counts defects by criticality and compares them against the plan's defect limits to produce an Accept or Reject decision.
Expandable Cards
Each characteristic appears as a collapsible card. Tap to expand and reveal the measurement input or pass/fail buttons. Cards show a green check or red cross to track completion at a glance.
Real-Time Validation
Variable characteristics show the measured value immediately against the tolerance range. Values within spec turn green; out-of-spec values turn red — no separate calculation needed.
Automatic Decision
On submit, TotalApp counts defects per criticality level, compares them to the plan's limits, and sets the lot decision to Accept or Reject. A banner displays the verdict with the defect breakdown.
NCR Linkage
A rejected lot stores the NCR ID once a Non-Conformance Report is created. Inspectors can navigate directly from the checklist to the open NCR.
Smart Progress Tracking
The progress bar counts only genuinely completed measurements — variable characteristics require a measured value, attribute characteristics require a pass/fail decision. Untouched rows do not advance the counter, giving an accurate completion percentage.
Starting an Inspection
- Open Quality Operations → Quality Checklist.
- Click Start Inspection (top-right). A modal appears.
- Select the Inspection Plan from the dropdown (only Active plans are listed).
- Enter the Lot Number (e.g.
LOT-2025-042) and the Inspector Name. The Inspector Name field auto-populates with the currently logged-in user's name — no manual entry needed. - Optionally enter a linked Work Order ID.
- Click Begin Inspection. The checklist opens in the detail panel with all characteristics ready for input.
Lot Number Format
Use a consistent lot numbering format (e.g. LOT-YYYY-NNN) to make checklists searchable and to ensure traceability records link correctly. The lot number is also the primary key for the Traceability screen's forward search.
Recording Measurements
In the detail panel, each characteristic is shown as a card. The card header displays the characteristic name, its criticality badge, and whether it has been recorded (green check) or not (grey cross). Click a card to expand it.
Variable Characteristics
Enter the measured value in the numeric input. The system immediately compares it against the plan's Min and Max values:
- Within spec → input border turns green, result shows PASS in green.
- Outside spec → input border turns red, result shows FAIL in red.
An optional Notes field below the input lets the inspector record context (e.g. "Measurement taken at ambient 22°C").
Attribute Characteristics
Two full-width buttons replace the numeric input: ✓ Pass and ✕ Fail. The selected button highlights in green or red. Notes can still be added — required when the result is Fail to capture what was observed.
Auto-Save
Each measurement is saved to the server as soon as it is entered. Closing the browser and returning later will restore all measurements recorded so far — the checklist status stays as In Progress until Submit is clicked.
Accept / Reject Decision Engine
When the inspector clicks Submit Inspection & Decide, TotalApp runs the following logic:
- Count failed characteristics for each criticality: Critical, Major, Minor.
- Compare each count against the plan's defect limits.
- If any criticality count exceeds its limit → Reject.
- If all counts are within limits → Accept.
| Decision | Condition | Next Step |
|---|---|---|
| Accept | All defect counts ≤ plan limits | Lot moves to next operation or warehouse receipt |
| Reject | Any defect count exceeds its plan limit | Create a Non-Conformance Report to manage the lot disposition |
The decision banner in the detail panel shows the verdict alongside the full defect breakdown (Critical N · Major N · Minor N) so the inspector can confirm the count.
Checklist List View
The left side of the screen shows all checklists in a sortable table. Use the status filter tabs to quickly isolate:
- In Progress — checklist created but not yet submitted.
- Accepted / Rejected — submitted and decided.
The search bar filters by lot number or product name. Clicking a row opens its detail panel.
AI Assistant
Quality Checklist includes a right-edge AI Assistant panel that reviews your current checklist list — lot, product, status, decision, inspector, inspection date, measurement progress, and defect counts — and answers natural-language questions about it.
Progress Review
Flags checklists stuck in progress for a long time, or with very low measurement completion.
Decision Analysis
Summarizes accept/reject rates across lots or products, and flags lots with unusually high defect counts.
Inspector Workload
Summarizes how many checklists each inspector has open or completed.
Trend Spotting
Points out lots or products with repeated rejections that may need a root-cause (NCR) investigation.
Save Assistant Answers as Reports
Any assistant response can be saved directly to My Reports with one click, so a progress or workload summary doesn't have to be re-generated later.