How to Run In-Process Quality Control That Catches Defects Before They Become Batch Rejections

Who This Is For

You manage quality at an FMCG or manufacturing plant. In-process quality checks are supposed to happen at critical control points during each shift. In practice, a paper form gets filled in at the end of the shift from memory — and submitted to QC as if it represents real-time monitoring. Defects that should have been caught at the line consistently surface at finished goods inspection instead, by which point you're looking at quarantine and scrap costs.

What You Can Achieve

• Quality checks are captured at critical control points during production — numerical readings taken at the time they happen, not reconstructed from memory at the end of the shift
• Out-of-spec results are flagged immediately, so production can be paused and investigated before the entire batch is affected
• ISO 9001 auditors see structured, time-sequenced quality evidence per batch, per line, per shift — not a binder of end-of-shift forms with indistinguishable timestamps
• CAPA tracking is built into the quality check record — non-conformances are documented and attributed at the point of discovery, not raised retrospectively
• Batch rejection rates drop when defects are caught at the CCP rather than at finished goods inspection, when it's already too late to prevent the loss
• Per-line and per-shift quality trends become visible over time, so process improvements are targeted at actual patterns rather than gut feel

The Hakiki Workflow

1. 1
   Production Line Selection Single Select

   Select the production line being inspected — enables per-line quality tracking and CAPA assignment

2. 2
   Batch ID Text

   Enter batch ID from the batch manufacturing record — ties all QC data to the specific batch

3. 3
   Shift Single Select

   Select: Morning / Afternoon / Night — enables shift-level quality analysis

4. 4
   pH Reading Text

   Enter pH value — target: 7.0 ± 0.5. Out-of-range triggers a CAPA note requirement

5. 5
   Viscosity Within Specification Boolean

   Confirm viscosity has been tested and is within the specification range for this product

6. 6
   Density Check Result Text

   Enter density measurement (g/mL) — compared against product specification

7. 7
   5 Random Sample Weights Text

   Enter weights of 5 randomly selected units (grams) — all must be within ±2g of target fill weight

8. 8
   All Weights Within Tolerance Boolean

   Confirm all 5 weights are within the ±2g tolerance — if not, production is paused for investigation

9. 9
   Label Print Quality Boolean

   Confirm label print is clear, correctly aligned, and batch/expiry information is legible

10. 10
    Seal Integrity Test Boolean

    Confirm product seal is intact and meets integrity specification — no leaks or deformation

11. 11
    Sample Pack Photo File Upload

    Photo of sample pack from this batch check — visual record of product at point of inspection

12. 12
    QC Technician Sign-Off Boolean

    QC Technician confirms batch check is complete and results are accurate — with technician ID and timestamp

13. 13
    CAPAs Raised Boolean

    Record whether any Corrective and Preventive Actions need to be raised based on this check

14. 14
    CAPA Notes Text

    Document the specific non-conformance and proposed corrective action — required if CAPAs is YES

HAKIKI Features Used