Blog Posts Process Analysis

Requirements – Quality Assurance (QA)

Blog: Biz-Performance, David Brown

Requirements – Quality Assurance (QA)


The Quality Assurance (QA) Application performs the following major functions:
  • Captures “screening” information from selected, incoming components (e.g., integrated circuits)
  • Maintains a complete quality history on all screened components
  • Captures reject/rework information on WIP subassemblies
  • Monitors reason for return codes on all rejected/returned goods
  • Monitors quality levels of all inhouseinspected, inhouse assembly, contractinspected, contract assembly and subassembly vendor items.
The QA application is integrated into the Warranty Tracking application to assist in diagnosing any qualityrelated problems in direct customer returned goods.


  • Capture online all relevant QA screening information (e.g., quantity inspected, quantity rejected and rejection code(s)) for:
    • Receiving inspection
    • WIP
    • MRB/QA hold
  • Maintain a historical file of inspection information by contractor or vendor by part number for a minimum of months by:
    • Quantity of last batch
    • Size of last inspection sample
    • Number of rejects in last batch
    • Reject percentage
    • Disposition of last batch
    • Quantity purchased YTD
    • Quantity purchased last months
    • YTD reject rate
    • Month reject rate
  • Capture online and report relevant quality information (e.g., quantity inspected, quantity rejected, reason for rejection) by:
    • Part number
    • Serial number
    • Purchase order
    • Work order
    • Lot/date code
    • Contractor/vendor
    • Failure code/category
    • Routing operation
  • Identify production contractor or vendors that experience significant quality problems via direct reporting
  • Identify operations (including those of outside contractors) that experience significant yield losses
  • Compute an average quality rating for a contractor/vendor by product class
  • Report on the quantity and type of defects by:
    • Operator
    • Contractor/vendor
    • Date/lot combination
    • Machine
    • Work center
    • Product
    • Serial number
    • Type of failure
  • Accommodate both discrete and repetitive manufacturing quality standards concurrently
  • Assign all incoming items requiring inspection to a QA inventory hold location (thus allowing for easier inventory tracking)
  • Transfer all rejected items to MRB or other QA hold inventory location for final disposition and processing of the defective/discrepant items
  • Generate online, ad hoc inquiries or reports for the QA database
  • Maintain product failure rates and failure reasons on components sent to outside contractors for quality or environmental testing
  • Prevent rejected items from being used in Inventory/MRP planning
  • Monitor online engineering data or quality data results and alert operator at point/time of entry with appropriate message, if readings and/or inspection results are out of acceptable preestablished control limits
  • Automatically place work order lots/batches on hold by reason at point/time of quality results data entry based on preestablished control limits
  • Report on relevant quality information for:
    • Receiving inspection
    • WIP inspection
    • Final inspection
  • Tie a component failure that occurs in production back to a specific contractor/vendor shipment and/or lot
  • Report on vendor/contractor product quality based on the capture of WIP quality results
  • Compute the costs of quality based on the following inputs:
    • Quality inspection costs
    • Quality prevention costs
    • Costs of failures
    • Costs of repairing failures
    • Costs of warranty tracking
    • Costs of warranty repairs
  • Specify a hold on vendor/contractor invoice payments based on QA inspection failure
  • Download a defined set of quality data items in a matrix format to a PC for graphing and trends correlation analysis

Field Sizes

  • Part number
  • Serial number
  • Contractor/vendor purchase order number
  • Contractor/vendor number
  • Test values (average resistance, capacitance, etc.)
  • Sample size
  • Date inspected (MM/DD/YY)
  • Inspector
  • Quantity accepted
  • Quantity rejected
  • Rejection code
  • Contractor/vendor lot number
  • Contractor lot/date code
  • Lot size
  • Inspection time
  • Date received


  • Daily Inspection Report – Details the quantity inspected, quantity rejected, rate (%) and reason(s) for rejection by:
    • Part number
    • Contractor/vendor number
    • Purchase order
    • Work order
    • Work center
    • Failure type
  • Part History Report – Printed as required, lists the quality history for a specified time period for specified items. The report data includes date inspected, log number, contractor/vendor number, contractor/vendor name, lot quantity, quantity inspected, quantity rejected, reject rate, lot rating, etc.
  • Monthly Quality Report – Dollarizes (by P/O unit price) the quantity rejected by component/subassembly numbers by vendor (or work center) for the current month and prior 11 months
  • Vendor Quality Report – Prepared for all vendors showing part quantities delivered, rolling and last month vendor quality rating, and the total costs of quality
  • Ad Hoc Reports – Ability for user to define specific data elements, sorts, comparisons and calculations to be displayed on reports using data obtained from the quality results database
  • Work Center Quality Report – Prepared for all work centers showing part quantities produced, rolling and last month quality rating, and total costs of quality


  • Receiving Traveler/Inspection Ticket – Document containing PO item receipt data with space to record item QA disposition
  • ECN – Engineering change notice informing QA of changes to item specifications

Audit Trails

  • Historical file of screening information by vendor by part number for a minimum of 24 months continuing: quantity of last batch, number of rejects, reject %, and quantity purchased YTD


  • Inventory Control – Rejected components and subassemblies are held in MRB or hold inventory status until an appropriate disposition is indicated
  • Purchasing – Pertinent P.O. line item records are updated to reflect quantity inspected, quantity rejected and disposition
  • Accounts Payable – A contractor/vendor invoice for the rejected items cannot be paid in full without a specific override
  • Shop Floor Control – Pertinent work order records are updated to reflect the quantity inspected, quantity rejected and disposition reason

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