Automation · Operations
Quality control in production without paper and Excel
Checklists on a phone at the line, non-conformities with an owner and a deadline, and batches you can trace one step back and one step forward. We build it on top of the accounting software or ERP you already have. The data stays in your system.
Does this sound like your quality control?
At smaller manufacturers, quality often lives on paper, in Excel and in e-mail. The goal is for the record to be created at the line and to be found without digging through binders.
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“We fill in the checklist at the end of the shift, after the fact.”
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“The customer wants an 8D within 10 days and we piece it together from e-mails.”
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“We don’t know which batch of granulate the returned lot came from.”
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“We can’t file a claim with the supplier because we have no photos and no numbers.”
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“A label with the wrong date went out because nobody checked it.”
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“Before an audit we spend a week looking for records.”
Flow
How quality control runs through production – and where we monitor it
At every point we automate recording, evaluation and alerts. Decisions about the product, the supplier and the customer stay with people.
- 01
Receiving
Incoming inspection on a phone or tablet. The batch and shelf life are recorded with the goods receipt, and a delivery marked NOK goes to quarantine.
Person: Decides whether to release the material or file a claim with the supplier.
- 02
Line
A checklist with tolerances. A value outside the limit is evaluated immediately and the supervisor gets an alert.
Person: Measures and records at the machine, not at the end of the shift.
- 03
Non-conformity
A QR code on the machine opens a form: defect, photo, quantity. A task with an owner and a deadline is created.
Person: Decides what happens to the non-conforming product and on the corrective action.
- 04
Output
Final inspection and label check. Only batches with an OK check are offered for shipping.
Person: Releases the lot for shipping.
- 05
Complaints and reports
Complaints are linked to the batch and the customer. A Pareto of non-conformities and the status of actions in one place.
Person: Decides what to tackle first.
6 quality control modules
You don’t have to take everything. We start with what hurts you most.
Checklists and measurement records
A digital quality control checklist on a phone or tablet at the line: incoming, in-process and final inspection, photos and tolerances with OK/NOK evaluation. Outside the limit, the supervisor gets an alert.
Non-conformity register and corrective actions
Recording a non-conformity right at the machine, quarantine of the non-conforming product, a corrective action with an owner and a deadline, and a check whether the action worked.
MoreComplaints and 8D reports
Customer complaints and claims against suppliers in one workflow with steps D1–D8 following the VDA methodology. The 8D report is built from data, photos and deadlines, not from e-mails. Connected to complaints in your ERP.
Batch traceability
Material batch → production lot → shipment → customer. Tracing one step back and one step forward, blocking, a basis for a recall and mock recalls.
MoreAI quality control: labels, codes, completeness
A photo station with an AI model checks the label, EAN, best-before date, batch and completeness of the pack. For a high-speed line we connect an industrial camera through a machine vision integrator.
Quality reporting
Pareto of non-conformities, PPM, cost of poor quality and supplier ratings. Documentation for an ISO, IFS or BRC audit without a week of searching.
What do you run on?
Accounting software and ERPs can do more with batches, complaints and incoming inspection than most companies use. Here is what is possible.
POHODA
Tracking numbers (batches or serial numbers) and expiry dates on goods receipts, issue slips, production and complaints. XML import of goods receipts, issue slips, transfers and production. The Complaints module for customer, purchase and stock complaints.
ABRA Gen
Batches and serial numbers on a stock document line, which can also be added later. A goods receipt with the statuses Planned / To be checked / Done for incoming quality inspection, which according to the vendor can be controlled by a script or via the Web API. Supplier point ratings and a complaints warehouse.
ABRA Flexi
Batches, expiry dates and serial numbers on stock movement items, balances by batch via the REST API. Complaints as a type of received order with a complaints warehouse. Webhooks on changes.
Raynet CRM
A customer complaint as a deal or a task with custom fields. Webhooks and custom action buttons start the complaint workflow.
Quality system (CAQ)
CAQ systems have modules for non-conformities, 8D, measuring equipment and audits. PALSTAT CAQ lists integration with common ERPs, KTK QMS import of XLS/XML/CSV or an API, EISOD X integration with ERP and MES.
Camera and AI model
For a photo station, a camera or a phone with controlled lighting and an AI model, either ready-made in the cloud or trained on your samples.
You only keep quality records on paper and in Excel? That is a starting point too. In the audit we tell you whether it is enough to start with forms and one spreadsheet.
When you don’t need us
We don’t sell our own quality system and we don’t do certifications. When an off-the-shelf solution is enough, we tell you.
- You are a small company and only need a few checklists
- There are ready-made apps with a monthly plan for checklists or HACCP records. If they are enough for you, we recommend them and build nothing.
- You already have the features in your license
- POHODA, ABRA Gen and ABRA Flexi can all handle batches and expiry dates, and POHODA and Flexi both record complaints. First we switch on what you already pay for.
- You are an automotive supplier and need FMEA, PPAP, MSA and SPC
- For that we recommend a CAQ system; we don’t build it custom. We connect it to your ERP and add data collection from the line.
- You are looking for camera inspection of surface defects at high speed
- That is a job for a machine vision integrator and an industrial camera. We add what goes around it: data, the non-conformity workflow and the ERP connection.
We handle quality control in our own operation too
We record batches and hygiene checks with limits in our own packing facility in Kuřim.
Batch traceability in our packing facility
In our own packing facility in Kuřim we record every batch through simple forms on a phone. For each batch (LOT) we can trace the raw material delivery, its shelf life and who the batch was shipped to, and the system itself makes sure that no raw material in quarantine or past its best-before date gets into packing.
Packaging and logistics division Our own operations · PackLabsPackLabsApp
The operations app of our packing facility in Kuřim: shifts, training signed on a phone, hygiene checks with limits, QR labels and the order plan. In Czech and Ukrainian.
Automation referencesHow it works
- 01
Free audit
30 minutes. How you handle inspections, non-conformities, complaints and batches today, and in which systems.
Output: Recommended next step
- 02
Inspection map
We go through paper sheets, spreadsheets and e-mails from receiving to shipping – on site or by video call.
Output: Module proposal and price
- 03
Pilot on one line
One line or one type of inspection. We first test AI inspection on your photos. We change live data in your ERP only after your approval.
Output: Verified flow
- 04
Rollout
Training right at the line. The form has to be faster than paper, otherwise nobody will use it.
Output: Inspections in operation
- 05
Maintenance
We watch for failures and adjust the checklists as production changes.
Output: Ongoing support (optional)
Frequently asked questions
Do we have to buy a new quality management system (QMS) for this?
Does it work at a line without Wi-Fi?
Can you do an 8D report according to VDA?
How fast can we trace a batch?
Is AI quality control reliable?
Will this make us compliant with legislation and standards?
What if our POHODA has no batch tracking?
How much does it cost and how long does it take?
Can you also do our packing and labeling?
Enquiry — Quality control
Tell us what you are dealing with. We start with a free 30-minute audit.