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

YouTube: Process Rejection /Quality Control Analysis

🧭 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.

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🛠️ 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 standardization🏆 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.

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❌ 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.

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🧾 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.

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📤 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).

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🧮 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.

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🔬 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.

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📈 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📅.

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✅ 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.

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🚀 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🔄.