In-Process Inspection Log Worksheet
In-process inspection catches drift while the job is still running. This log records each check by job, operation and feature, calculates the defect rate and keeps a clear record of when the line was stopped.
| Date / time | Job / WO | Operation | Feature checked | Pieces checked | Defective pieces | Defect rate | Status | Inspector | |
|---|---|---|---|---|---|---|---|---|---|
0% | |||||||||
20% | |||||||||
0% | |||||||||
25% | |||||||||
0% |
Add one row per inspection event. Use Watch when a result is near the limit and Stop and contain when a defect needs the line stopped and suspect parts quarantined. This log does not replace SPC charts for variable data.
Build a live defect-rate dashboard
Optional: we can discuss pulling in-process results from your ERP or MES into a dashboard with alerts.
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How to use the log
Add a row each time an inspector or operator checks pieces at an operation. Fill in the time, job, operation, the feature you checked, the number of pieces checked and the number found defective. The defect rate is calculated for you and the totals show the day's overall rate. Use the status column to flag results that need attention. Export to Excel at the end of the shift or day and file the sheet with the job traveler.
- One row per check, not one row per day.
- Name the actual feature checked so trends can be traced.
- Record the action taken beside any Stop and contain status.
Choosing frequency and sample
Frequency and sample size should come from the control plan, based on process capability and risk. A stable process with a high Cpk might be checked hourly with 3 to 5 pieces, while a new or sensitive process might be checked every 15 minutes or after each tool change. For variable characteristics, plot the values on an X-bar and R chart instead of only counting defects. Counting is appropriate for visual defects, go or no-go checks and attribute features.
Reacting to a bad check
When a check fails, the reaction plan in the control plan applies. A common one is to stop the process, quarantine all parts made since the last good check, correct the cause, make a first piece, and resume only after approval. The time between checks determines how much product is at risk, so widely spaced checks lead to larger containment. Record the quantity contained and the final disposition on a nonconformance report.
Common mistakes
Typical issues are logging only passes, rounding defects to zero, checking the same easy feature each time and never the problem one, and leaving the log at the inspection bench instead of with the job. Another is mixing different operations in one row, which hides the source of defects. Keep the data honest: a log full of perfect results with no watch items often means checks are not really being done.
Frequently Asked Questions
How often should in-process inspections be done?
The control plan sets it. Common patterns are first piece, then hourly or every set number of parts, plus a check after any tool change or adjustment. Frequency should reflect capability, risk and the cost of containment if a problem is found.
What is the difference between in-process and final inspection?
In-process inspection happens during production to catch problems early and keep the process in control. Final inspection checks the finished product against requirements before shipment. Final inspection alone finds problems late, when the cost of scrap and rework is higher.
Should operators or inspectors do in-process checks?
Both are used. Operator self-inspection gives the fastest feedback, while an independent inspector provides verification, especially for critical characteristics. The control plan should state who is responsible for each check and how results are recorded.
Can this log replace SPC?
No. It counts defects and flags status, which is useful for attribute checks. SPC charts for measured values show trends and process capability before parts go out of tolerance. Many plants use both: SPC for key dimensions and a log for visual and attribute features.
If shop floor checks are already entered in your MES or ERP, we can show how to build a defect-rate dashboard and alert directly from that data.
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