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Catch it at the operation, not at dispatch.

Inspection plans and quality points across incoming, in-process and final inspection — with non-conformance, root cause and corrective action tracked to closure and to cost.

The problem

Quality failures found at final inspection have already consumed the full cost of the product. The same defect caught at the operation that caused it costs a fraction — but only if there is a check at that operation.

Cost of poor quality is rarely isolated in manufacturing accounts. It is absorbed into scrap allowance and labour hours, which is why it never appears as a problem worth solving.

Core workflow

Check to closed corrective action.

01
Inspection plan
Characteristics, methods, frequency and limits.
02
Incoming QC
Supplier material checked before it enters stock.
03
In-process
Quality points at defined operations.
04
Non-conformance
NCR raised with disposition and cost.
05
Root cause
Investigated and attributed to a process step.
06
Corrective action
Owner, due date, verification and closure.
What it covers

Inspection

Inspection and test plansIncoming, in-process and final QCSampling plansMeasurement and tolerance captureCertificates of analysis

Non-conformance

NCR register and dispositionScrap, rework, use-as-is, returnSupplier quality claimsCustomer complaintsCost of poor quality

Improvement

Root cause analysisCorrective and preventive actionEffectiveness verificationFirst-pass yield trendQuality records for audit
Operational outcomes
96.4%
First-pass yield
−2.8%
Cost of poor quality
At the operation
Defects caught, not at dispatch
100%
NCRs closed with verification

Ranges observed on Al Jawad engagements. Targets agreed in assessment.

Isolate your cost of poor quality.

We separate scrap, rework and re-inspection from standard allowance for one month and put a number on it.