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πŸ›  Designing In-Process Quality Control (IPQC) in Next Plus

Alex Merkin avatar
Written by Alex Merkin
Updated over a month ago

πŸ“– What is IPQC and Why It Matters

In-Process Quality Control (IPQC) means monitoring and verifying quality during production, not just at the end. Instead of finding defects after a batch is complete, IPQC ensures every unit, step, or parameter is checked at the right time.

Why manufacturers need IPQC:

  • Prevention over correction β†’ catch problems before they multiply.

  • Compliance assurance β†’ required by standards such as ISO 9001, AS9100, IATF 16949, FDA 21 CFR Part 11, HACCP.

  • Customer confidence β†’ every inspection is traceable to who did it, when, and how.

  • Continuous improvement β†’ defect logs become a source of process learning.

In a lean environment, IPQC is essential: it reduces waste (scrap, rework), shortens feedback loops, and empowers operators to be active participants in quality, not passive executors.

🧩 The Building Blocks of IPQC in Next Plus

  1. Workflows β†’ Steps β†’ Fields

    • Workflows are structured processes.

    • Steps guide the operator through tasks.

    • Fields in steps capture values (numeric, pass/fail, notes, signatures).

  2. Forms β†’ Fields

    • Forms are standalone entities with structured fields.

    • Used for inspections, audits, or defect reporting.

    • Can be attached to steps, triggered automatically, or assigned separately.

  3. Triggers

    • Define what happens if conditions are met or failed.

    • Example: If measurement outside tolerance β†’ open NCR form + notify QA.

Together, these tools let Editors design quality into the process itself.

πŸ” Types of IPQC with Practical Examples

Attribute Checks (Pass/Fail)

  • Editor setup: Add Pass/Fail + photo field in workflow.

  • Example: In a food packaging line, operators confirm label correctness and upload a photo.

  • Operator view: One click + photo.

  • QA value: Traceable evidence for audits.

Variable Measurements (Numeric)

  • Editor setup: Numeric field with min/max validation.

  • Example: In electronics assembly, torque must be 9.8–10.2 Nm.

  • Operator view: Can’t proceed with 9.5 Nm.

  • QA value: Automatic defect logging, full traceability.

Sampling Inspections

  • Editor setup: Configure every nth unit/batch for inspection.

  • Example: In plastic molding, the first piece of each batch is measured.

  • Operator view: Prompts appear only when needed.

  • QA value: Reliable statistical checks without slowing throughput.

Process Parameter Monitoring

  • Editor setup: Link workflow to OPC UA machine data with tolerance rules.

  • Example: In food processing, cooking temp must stay β‰₯72Β°C.

  • Operator view: No manual input β€” alerts if machine drifts.

  • QA value: HACCP compliance with automated logs.

Certified Sign-Offs

  • Editor setup: Step requires certified inspector signature.

  • Example: In aerospace welding, only certified QA can sign off.

  • Operator view: Step blocked until inspector signs.

  • QA value: Compliance with AS9100.

Defect Logging & Escalation

  • Editor setup: Trigger to open NCR form on failed check.

  • Example: In metal machining, surface finish out of spec β†’ NCR form opens.

  • Operator view: Guided to document defect properly.

  • QA value: Standardized defect reports, immediate escalation.

🏭 Industry Blueprints for IPQC in Next Plus

🍞 Food & Beverage (HACCP focus)

  • Key checks: cooking temperature, sanitation, packaging seal.

  • Setup: numeric fields with validation + OPC UA machine integration.

  • Operator experience: prompted to record or confirm values per batch.

  • QA benefit: automated HACCP logbooks with timestamps.

πŸš— Automotive (IATF 16949 focus)

  • Key checks: torque audits, dimensional measurements, label scans.

  • Setup: inline numeric fields, sampling inspections (e.g., 1/10 parts).

  • Operator experience: torque values must be in range before proceeding.

  • QA benefit: SPC-ready data for control charts.

✈️ Aerospace (AS9100 focus)

  • Key checks: weld inspections, critical dimensions, certified sign-offs.

  • Setup: steps requiring QA-certified e-signatures.

  • Operator experience: step blocked until inspector signs.

  • QA benefit: compliance evidence for every critical process.

πŸ’» Electronics (ISO 9001 focus)

  • Key checks: solder joint quality, torque of connectors, ESD checks.

  • Setup: attribute checks (pass/fail + photo) + torque measurements.

  • Operator experience: guided step-by-step with mandatory inputs.

  • QA benefit: rapid identification of defect trends across operators or shifts.

⚠️ Common Pitfalls

  • Overloading operators β†’ balance automation and sampling.

  • Loose tolerances β†’ miss real issues; too strict β†’ false alarms.

  • Unlinked forms β†’ defects get logged without context. Always connect NCRs to work orders.

  • Generic fields β†’ design forms that capture the right defect details (lot, supplier, root cause).

βœ… Key Takeaways

  • Editors are the architects of in-process quality in Next Plus.

  • Operators see clear, enforceable checks they can’t skip.

  • QA Inspectors receive clean, validated, traceable data.

  • Managers can prove compliance instantly with dashboards and exports.

Next Plus offers the complete IPQC toolkit:

  • Workflows β†’ guide operators through required checks.

  • Forms β†’ capture structured data.

  • Validation rules β†’ prevent incorrect entries.

  • Triggers β†’ escalate issues automatically.

  • Certifications β†’ enforce role-based sign-offs.

  • OPC UA β†’ automate machine parameter monitoring.

  • Dashboards β†’ analyze trends and demonstrate compliance.

When you design IPQC thoughtfully, you’re not just preventing defects β€” you’re embedding quality as a living part of every process.

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