What can you achieve with it?

• 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

Heavy-Procedure IndustriesFMCG Manufacturing Plant

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.

The problem

An end-of-shift paper quality form submitted to QC isn't an in-process control system — it's a reconstruction of what someone thinks they checked eight hours ago, written to satisfy a documentation requirement. By the time a defect shows up at finished goods inspection, the entire batch may need to be quarantined or scrapped. The cost isn't just the wasted product: it's the production time, the raw materials, and the delivery commitment you're going to miss. ISO 9001 auditors draw a clear distinction between quality documentation and a quality management system. Submitting paper forms at end of shift is documentation. Capturing structured quality data at critical control points during production — in real time, with numerical readings and photo evidence — is a quality management system. The certification outcome, and your actual defect rate, depends entirely on which one you can demonstrate.

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 workflow in Hakiki

1
Production Line SelectionOne choice
Select the production line being inspected — enables per-line quality tracking and CAPA assignment
2
Batch IDText
Enter batch ID from the batch manufacturing record — ties all QC data to the specific batch
3
ShiftOne choice
Select: Morning / Afternoon / Night — enables shift-level quality analysis
4
pH ReadingText
Enter pH value — target: 7.0 ± 0.5. Out-of-range triggers a CAPA note requirement
5
Viscosity Within SpecificationYes or no
Confirm viscosity has been tested and is within the specification range for this product
6
Density Check ResultText
Enter density measurement (g/mL) — compared against product specification
7
5 Random Sample WeightsText
Enter weights of 5 randomly selected units (grams) — all must be within ±2g of target fill weight
8
All Weights Within ToleranceYes or no
Confirm all 5 weights are within the ±2g tolerance — if not, production is paused for investigation
9
Label Print QualityYes or no
Confirm label print is clear, correctly aligned, and batch/expiry information is legible
10
Seal Integrity TestYes or no
Confirm product seal is intact and meets integrity specification — no leaks or deformation
11
Sample Pack PhotoFile upload
Photo of sample pack from this batch check — visual record of product at point of inspection
12
QC Technician Sign-OffYes or no
QC Technician confirms batch check is complete and results are accurate — with technician ID and timestamp
13
CAPAs RaisedYes or no
Record whether any Corrective and Preventive Actions need to be raised based on this check
14
CAPA NotesText
Document the specific non-conformance and proposed corrective action — required if CAPAs is YES

Hakiki features used

Single select line and shiftText numerical readingsBoolean pass/failFile upload for sample photosCAPA tracking via conditional text stepsQC technician attribution

More in Heavy-Procedure Industries

Private Hospital

How to Run the WHO Surgical Safety Checklist Digitally — and Make It Count for Accreditation

Pharmaceutical Manufacturer

How to Run GMP Batch Release Documentation That Passes WHO and KEBS Audits

Regional Airline

How to Run Pre-Flight Inspections With a Digital Audit Trail That Satisfies KCAA

Set this up for your team.

Start a free trial and build the workflow above. No card needed.

Start free trial Talk to us