How to Set Up Inspection Plans | SyteLine Guide

Creating Inspection Plan Headers

Navigate to Quality > Inspection Plans to access the Inspection Plan form. Each plan requires a unique plan ID, revision level, and effective date range. You can associate plans with specific items, item groups, or vendor-item combinations.

The plan header also defines the inspection type, receiving, in-process, or final, and the default disposition codes for accepted and rejected materials. 4.

Access the form via Quality > Inspection Plans and create a new plan with unique ID and revision
Set the inspection type field to Receiving, In-Process, or Final to control when inspections trigger
Define AQL levels (0.065 to 6.5) and sampling plan references on the header for lot-based inspection
Link the plan to specific items using the Item/Inspection Plan cross-reference form

Defining Quality Characteristics and Tests

Within each inspection plan, add quality characteristics that define what gets measured or evaluated. Navigate to the Characteristics tab to add variable measurements (dimensions, weight, temperature) or attribute checks (visual, pass/fail). Each characteristic requires a target value, upper and lower specification limits, and the measurement unit.

For variable data, configure the control chart type (X-bar/R or X-bar/S) and subgroup size. SyteLine supports linking characteristics to gauge IDs for calibration traceability per ISO 10012.

Add variable characteristics with target values, USL/LSL tolerances, and measurement units
Configure attribute characteristics for visual or go/no-go inspections with accept/reject counts
Set sampling frequency rules, 100% inspection, skip-lot, or AQL-based sampling per characteristic
Link each characteristic to a specific gauge or instrument ID for calibration traceability

Assigning Plans to Operations and Triggering Inspections

Inspection plans must be linked to production operations or purchase order receiving steps to trigger automatically. Use the Item/Inspection Plan form to associate plans with routing operations by specifying the operation number and work center. For receiving inspections, link plans through Vendor/Item parameters so inspections generate automatically when PO receipts post.

Configure the Results Entry form preferences to enable barcode scanning for shop floor data collection. The system generates inspection orders with lot tracking and supports SPC (Statistical Process Control) chart generation from collected data.

Link plans to routing operations via Item/Inspection Plan cross-reference with operation sequence numbers
Enable auto-generation of inspection orders on PO receipt by setting vendor/item inspection flags
Configure the Inspection Results Entry form for shop floor data collection with barcode support
Review SPC charts and Cpk/Ppk capability indices from Quality > Analysis > Capability Studies

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SyteLine Admin Forms and Utilities Reference

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The forms and server utilities a SyteLine 9 or 10 on-prem admin uses for configuration, background tasks, events, replication, customization and security, with what each is for.

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Name	Type	Area	What you do there	How to open
Configuration Manager	Utility	Configuration	Create and edit configurations: application database, Runtime (Client) forms database, Objects metadata database, and configuration groups	Windows program on the utility server
Service Configuration Manager	Utility	Configuration	Set up the framework services on a server, including the accounts and settings they run with	Windows program on the utility server
LogMonitor	Utility	Configuration	Watch framework and IDO runtime log messages live while you reproduce a problem	Windows program on the server
InforDBCL	Utility	Configuration	Database command line utility for database tasks run outside the forms	Command line on the server
FormSync	Utility	Customization	Compare and merge forms, global objects and strings between forms databases, for example after an upgrade	Windows program on the utility server
App Metadata Transport	Utility	Customization	Export and import IDO and application metadata between environments	Windows program on the utility server
IDO Custom Assemblies	Form	Customization	Import compiled IDO extension class assemblies (DLLs) into the objects metadata	Open by form name
Background Task Definitions	Form	Background tasks	Define tasks that run on the server: reports, stored procedures, executables	Open by form name
Active Background Tasks	Form	Background tasks	See tasks queued or running now and cancel a stuck one (form ActiveBGTasks)	Open by form name
Background Task History	Form	Background tasks	See finished tasks with status, messages and run times (form BGTaskHistory)	Open by form name
Event Handlers	Form	Events	Define handlers that run actions when an IDO or application event fires	Open by form name
Event Handler Status	Form	Events	Check the state of handlers that ran for an event	Open by form name
Event Status	Form	Events	Check events that were raised and whether they finished, failed or wait	Open by form name
Event Global Constants	Form	Events	Maintain constants that event handlers and workflows read	Open by form name
Replication Rules	Form	Replication and BODs	Define which categories replicate to which site or to ION	Open by form name
Replication Management	Form	Replication and BODs	Run Regenerate Replication Triggers after changing rules	Open by form name
Replication Document Outbox	Form	Replication and BODs	See outbound BODs and replication documents waiting or failed	Open by form name
Replication Document Inbox	Form	Replication and BODs	See inbound BODs and replication documents and their errors	Open by form name
Replication Tool	Form	Replication and BODs	Run replication for selected objects, for example an initial load	Open by form name
Report Options	Form	Reporting	Set default options for a report, such as output format and print settings	Open by form name
Document Types	Form	Reporting	Maintain the document types used to classify attached documents	Open by form name
Users	Form	Security	Create users, set passwords, sites and group membership	Open by form name
Groups	Form	Security	Maintain authorization groups and their members	Open by form name
Object Authorizations for Groups	Form	Security	Grant or deny read, edit, insert, delete and execute on forms and IDOs per group	Open by form name
License Management	Form	Security	Apply licence documents and assign licence modules to users	Open by form name

Applies to SyteLine 9.x and CSI 10.x on-prem with the Mongoose framework. Forms open by name from the form search in the client; utilities are Windows programs installed on the utility or application server, so you need server access to run them. Form captions can differ slightly by release and language, so search on a key word such as Replication or Background if an exact name does not match. Your group needs authorization on each form.

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Frequently asked questions

Can SyteLine inspection plans support skip-lot inspection?

Yes, SyteLine supports skip-lot inspection through the Sampling Plan configuration. You can define skip-lot rules based on consecutive lot acceptance history, typically after 5-10 consecutive accepted lots, the system automatically reduces inspection frequency. The skip-lot level resets to full inspection after any lot rejection, following ANSI/ASQ Z1.4 switching rules for normal, tightened, and reduced inspection.

How do inspection plans integrate with SyteLine non-conformance reports?

When inspection results fail the defined acceptance criteria, SyteLine automatically generates a non-conformance report (NCR) linked to the inspection order. The NCR captures the defect type, quantity rejected, characteristic that failed, and measured values. Disposition options include return-to-vendor, rework, scrap, or use-as-is with engineering approval. Each NCR links back to the originating inspection plan for root cause traceability.

What sampling standards does SyteLine support for inspection plans?

SyteLine supports ANSI/ASQ Z1.4 (attributes) and Z1.9 (variables) sampling standards natively. You can configure inspection levels I through III, with special inspection levels S-1 through S-4 for destructive testing. Custom sampling tables can also be defined for industry-specific requirements. The system maintains lot size ranges from 2 to 500,000+ units with corresponding sample sizes and accept/reject numbers.

Need help implementing SyteLine inspection plans that comply with your industry quality standards? Netray consultants specialize in SyteLine quality module configuration for aerospace, automotive, and medical device manufacturers.

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How to Set Up Inspection Plans in SyteLine

Creating Inspection Plan Headers

Defining Quality Characteristics and Tests

Assigning Plans to Operations and Triggering Inspections

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