Quality Operations
End-to-end quality management — from inspection plan authoring and shop-floor checklists through non-conformance tracking, statistical process control, and full 4M lot traceability.
Overview
The Quality Operations module gives manufacturers a complete closed-loop quality system inside TotalApp. Define what to inspect, execute inspections on the shop floor, capture non-conformances when lots fail, monitor process stability with SPC charts, and prove compliance with forward and reverse traceability — all without leaving the application.
Inspection Plans
Build structured inspection plans with AQL sampling tables, characteristic definitions (variable or attribute), and defect limits per criticality level.
Quality Checklist
Execute plans on the shop floor with real-time pass/fail recording for each characteristic. The system auto-computes the accept/reject decision when the checklist is submitted.
Non-Conformance (NCR)
Track rejected lots through an open → assigned → analysis → disposition → approved → closed workflow, with root cause (6M), disposition decision, and CAPA action items.
SPC Charts
Plot variable-characteristic measurements against dynamically calculated control limits (UCL/LCL). Nelson rule violations are flagged automatically, and Cpk capability is calculated.
Traceability (4M)
Drill from any finished-good lot back to every material batch, machine, operator, and method revision used in its production — or run reverse queries from supplier lots.
Dual Style
Every screen supports the global Workstation (dark glass) and Enterprise (light corporate) visual modes — selectable in Settings → Appearance.
Module Location
Switch to Quality Operations mode using the mode switcher in the top header (shows "QO Mode"), or navigate directly from My Apps → Quality Operations. The mode can also be enabled and pinned in Settings → App Modes.
The Five Screens
| Screen | Purpose | Key Actions |
|---|---|---|
| Inspection Plans | Author and version inspection plan templates | 4-step wizard, AQL lookup, characteristic editor, plan detail view |
| Quality Checklist | Execute inspections on the shop floor | Card-by-card measurement entry, auto pass/fail, accept/reject decision |
| Non-Conformance (NCR) | Manage rejected lots from detection to closure | Status workflow, root cause (6M), disposition, CAPA items |
| SPC Charts | Monitor process stability over time | Canvas control chart, Cpk analysis, Nelson rule violations |
| Traceability (4M) | Forward and reverse lot genealogy | 4M tree (material/machine/operator/method), supplier recall simulation |
Typical Quality Workflow
These screens connect in a natural production quality loop:
- Design inspection plans — define which characteristics to measure, with what tools, and what the accept/reject thresholds are.
- Execute checklists — inspectors open a checklist from a plan, record measurements or pass/fail results for each characteristic, and submit to get an automatic lot decision.
- Handle rejections — a rejected lot automatically triggers (or the inspector manually creates) a Non-Conformance Report. The NCR moves through analysis, disposition approval, and corrective actions.
- Prevent recurrence — SPC charts reveal whether a process is drifting before it causes more rejections. Out-of-control signals generate Nelson rule violation alerts.
- Prove compliance — traceability records link every finished lot to its input materials, machines, operators, and method revisions, enabling rapid response to supplier recalls or customer audit requests.
Integration Points
| Module | Integration |
|---|---|
| Manufacturing | Work orders provide production lot context; operator and machine data feed traceability records |
| Warehouse | Incoming inspection checklists link to receipt lots; rejected lots can be quarantined |
| Purchase | NCR disposition "Return to Supplier" generates a purchase return |
| Project Management | CAPA action items can be linked to PM tasks for tracking |
| HR | Operator training and certification status is captured in traceability records |
Data Storage
All Quality Operations data is persisted via the server-backed JSON API at /api/data/quality-management. The store contains five top-level keys:
| Key | Contents |
|---|---|
inspectionPlans | Record of plan ID → InspectionPlan objects with characteristics, sampling plan, and defect limits |
checklists | Record of checklist ID → QualityChecklist objects with per-characteristic measurements and decision |
ncrs | Record of NCR ID → NonConformanceReport objects with root cause, disposition, and CAPA items |
spcViolations | Array of SPC rule violations detected against control limits |
traceabilityRecords | Record of finished lot → TraceabilityRecord with 4M linkages |
Server-Backed Persistence
Data survives page refreshes and is shared across browser tabs. The service layer in qualityManagementService.ts provides seed data on first load, so the module is immediately usable with realistic demo content.