# Process Rejection Study / Standard Instruction for Processes / Quality Control Parameter Setup

YouTube: [Process Rejection /Quality Control Analysis](https://youtu.be/N9HmAiAeaBI?si=fzWGEHbkCzQygMni)

### 🧭 **Overview**

In a structured production environment, maintaining consistent product quality, ensuring adherence to process instructions, and tracking reasons for rejection are crucial to operational success. This tutorial outlines how to manage:

* ✅ Job Order Instructions
* ❌ Production Rejections & Reasons
* 🔬 Quality Control (QC) Parameters
* 📊 Reports for process analysis and quality insights

This process is especially helpful in garment, textile, electronics, or any discrete manufacturing industry.

***

### 🛠️ **Step 1: Set Up Job Order Instructions**

#### 🔍 What Are Job Order Instructions?

These are **process-specific guidelines** that ensure production is carried out correctly and consistently. They help reduce **human error**❌, **improve product quality**🔧, and **maintain standardizatio**n🏆 **across batches**.

#### 📝 Example Instructions:

* 🪡“Use needle size 11 for lightweight fabric”
* 📏“Ensure 2-inch margin before stitching begins”
* 🧪“Run pre-wash test on dyed fabric”

#### 📌 How to Set Up:

1. Go to **Production**, then click on **Production Setups** and select **Setup Job Order Instructions** in your system.
2. Click ➕**Add New**.
3. Enter:
   * **Instruction Title**🏷️.
   * **Applicable Process**🔄 (e.g., Cutting, Stitching)
4. 💾**Save** the instructions.

> ✅ These instructions can now be linked to job orders at the time of creation, ensuring operators and supervisors are aligned.

***

### ❌ **Step 2: Define Rejection Reasons**

#### 🔍 Why Track Rejections?

Understanding **why items are rejected** helps identify recurring production issues—whether due to machines🛠️, materials🧵, or human error👷.

#### 📝 Common Rejection Reasons:

* 🩳Fabric torn during stitching.
* 🔁Stitch skipping.
* 📏Size mismatch.
* 🎨Print misalignment.

#### 📌 How to Set Up:

1. Navigate to **Production**, click and expand **Production Setups**, then select **Setup Production Rejection Reasons** option.
2. Add relevant reasons with clear names and descriptions.
3. Save them for future selection during production entry.

> 🧠 These reasons are linked during production receipt so you can run historical analysis later.

***

### 🧾 **Step 3: Create Job Order & Link Instructions**

A **Job Order**🧵 defines what is being produced, in what quantity, and through which processes.

#### 📌 How to Create:

1. Navigate to the **Production** option, then expand **Production Vouchers** and select **Job Order.**
2. Open **Job Order** screen.
3. Enter:
   * 🏷️Product Name
   * 🔢Quantity to be produced
   * 🔄Related Processes (e.g., Cutting → Stitching → Finishing)
4. ➕Add **Job Order Instructions** per process (select from the instruction master).
5. 💾**Save** the entry.

> 🔗 This ensures instructions flow with the job from one department to another.

***

### 📤 **Step 4: Issue the Job for Processing**

This is where you assign the job to a worker👷, team, or external party🌐.

#### 📌 How to Issue:

1. Go to **Production**, then select **Production Voucher** option and click on **Issue For Processing - First Process.**
2. Select:
   * 🛠️Process (e.g., Cutting)
   * 👥Worker or Team Name
   * 🔗Link the appropriate Job Order
3. Enter **issue quantity**💾 and **save**💾.

> 📦 This officially starts production and moves inventory to **WIP (work in process)**.

***

### 🧮 **Step 5: Record Production & Enter Rejections**

Once a process is completed (e.g., stitching), the team enters the output and any rejected items.

#### 📌 How to Enter:

1. Navigate to the **Production** section, then select **Production Vouchers** option and select **Receipts Against Issues - Internal.**
2. Open **Production Receipt**.
3. Enter:
   * Process Completed✅.
   * Produced Quantity.
4. In the **Rejection column**❌, press the **spacebar**.
5. Enter:
   * 🛑Rejection Reason (select from master)
   * 🔢Quantity rejected
6. 💾**Save** the document.

> 🔁 Multiple rejection reasons can be added for a single receipt if applicable.

***

### 🔬 **Step 6: Perform Quality Control (QC) Check**

The **Quality Control** department checks whether the product meets internal or client standards📏✔️.

#### 📌 How to Perform QC:

1. Navigate to the **Production** section, then select **Production Vouchers** option, and select **QC Document against Production Receipts.**
2. Open the **QC Entry** screen.
3. Select the related **Production Receipt**.
4. Click **Refresh**🔁 to fetch item data.
5. In the **QC Details** column, press the **spacebar**.
6. Enter:
   * 🧪Parameter Name (e.g., GSM, Tensile Strength).
   * ✍️Measured Value.
   * Result (Pass✅/Fail❌).
7. Save the QC report.

#### 📝 Example QC Parameters:

* Fabric GSM: 180 ± 5%
* Colorfastness Rating: ≥ 4
* Stitch Count: 9-10 stitches/inch

> 📊 These QC entries ensure transparency and help identify process weaknesses early.

***

### 📈 **Step 7: Monitor via Reports**

Several reports are available to monitor job health, quality, and rejection trends📉📈.

#### 📋💼 Key Reports:

| Report Name                         | Description                                                            |
| ----------------------------------- | ---------------------------------------------------------------------- |
| 🧾**Job Order Production Status**   | Shows produced vs. rejected quantities for each job                    |
| ❌**Rejection Reason Report**        | Lists top rejection causes and affected quantities                     |
| 🔬**Quality Control Summary**       | Tracks QC status by item, batch, or job order                          |
| 📊**Instruction Compliance Report** | (Optional) Verifies if job instructions were acknowledged and followed |

> 📌 Use these reports weekly/monthly to analyze trends and improve production efficiency📅.

***

### ✅ **Key Benefits of This Workflow**

* 🎯 **Standardization**: Ensures that every team follows the same production process.
* 🧠 **Root-Cause Analysis**: Helps isolate and correct frequent issues.
* ⏱️ **Efficiency**: Reduces errors, waste, and rework by providing structure.
* 📊 **Data-Driven Decisions**: Improves management oversight with real-time reporting.
* 📦 **Product Quality**: Enhances customer satisfaction by delivering consistent, high-quality output.

***

### 🚀 **Conclusion**

Implementing a structured approach for **job order instructions**, **rejection management**, and **quality control** is essential for **efficient** and **scalable📈 production.** These tools not only help prevent problems but also build a data-backed framework for continuous improvement🔄.


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