Patrol Inspection Round Worksheet
Patrol inspection catches drift between first piece approval and final inspection. This worksheet gives patrol inspectors a structured round sheet that flags out-of-tolerance readings and shows how close in-spec readings are to a limit.
| Time | Station | Job / WO | Characteristic | Lower limit | Upper limit | Reading | In spec (1 = yes) | Distance to nearest limit | Action taken | |
|---|---|---|---|---|---|---|---|---|---|---|
1 | 0.012 | |||||||||
1 | 0.03 | |||||||||
1 | 0.002 | |||||||||
0 | -0.003 |
A negative distance to nearest limit means the reading is out of tolerance. A small positive value is an early warning that the process is drifting toward a limit.
Digitize patrol checks on the shop floor
Optional: see how patrol readings can be captured on a tablet and linked to work orders.
Optional. The tool and every export work without this. No spam.
How to use the round sheet
On each round, add a row per check: time, station, job number and characteristic. Enter the lower and upper limits from the control plan or inspection instruction, then the reading. The in-spec column returns 1 or 0, and the distance column shows how much room is left before the nearest limit. In the action column, record what was done: parts held, operator notified or offset adjusted. Export at the end of the shift for the quality file.
Why distance to limit matters
A reading of 12.723 against an upper limit of 12.725 passes, but it leaves only 0.002 mm of room. Patrol records that only show pass or fail miss this. The distance column highlights drift early, so the inspector can ask for an offset adjustment before parts go out of tolerance. Many shops set an action line, for example at 75 percent of the tolerance, in the control plan. Use the distance column to apply it consistently.
- Negative distance means out of tolerance
- Small positive values call for a conversation with the operator
- Repeated small values on the same station suggest tool wear
Fitting it to your control plan
Patrol frequency, sample size and characteristics should come from the process control plan, not from habit. Typical patterns are hourly checks or checks every set number of parts, with extra checks after tool changes, setups and breaks. List the key characteristics only, since too many checks per round leads to rushed readings. When a reading fails, the plan should state the reaction: stop, contain parts back to the last good check, and notify the supervisor.
Common mistakes
Checking only the easy characteristics, backdating entries, and writing none in the action column when a reading was out of tolerance are the main failure modes. Containment must go back to the last good check, so the time column is essential. Do not overwrite a failed reading after adjustment, add a new row instead. If readings are consistently near one limit, review the process rather than relying on inspection to catch every escape.
Frequently Asked Questions
How often should patrol inspection happen?
As often as the control plan says. Common patterns are hourly or every fixed number of parts, with more frequent checks on unstable processes and after setup or tool changes. Base the frequency on process capability and the cost of escapes.
What is the difference between patrol and in-process inspection?
In-process inspection is checking during production in general. Patrol inspection is a roving inspector visiting stations on a schedule. Operator self-inspection is a third layer. The three work together under a control plan.
What should I do after an out of spec reading?
Stop the station, hold parts produced since the last good check, notify the supervisor, correct the cause and verify with a first piece check. Record the actions on the sheet and open a nonconformance if parts were affected.
Can I add more than one limit set?
Yes. Each row has its own lower and upper limit, so different characteristics and jobs can sit on the same sheet. Keep one sheet per shift or per line to stay readable.
If patrol results are collected on paper and typed in later, Netray can help bring shop floor checks into your ERP or MES so containment can be traced by work order.
Related Tools
Dimensional Inspection Record Worksheet
Enter nominal, plus and minus tolerance and the measured value for each dimension. Deviation and pass or fail are computed per row.
Quality & InspectionDefect Cost Tally Worksheet
Count defects by type and attach a cost per defect to see which failure modes drive the most scrap and rework cost.
Quality & InspectionInspection Work Instruction Template
A fill-in inspection instruction that tells inspectors what to check, with which gage, how often, and what to do on failure.
Quality & InspectionQuarantine Hold Tag Template
A printable hold tag that identifies suspect material, the reason for hold, where it is stored and who can release it.
More Quality & Inspection tools
See all- SAP QM Process Capability Cp Cpk Calculator
- SAP QM Lot Rejection Rate, PPM and Sigma Level Calculator
- SAP QM Gauge R&R Study Calculator
- SAP QM Cp and Cpk Capability Calculator
- Job Shop Material Certification Log Worksheet
- Job Shop First Piece Inspection Sign-Off Template
- Job Shop Scrap and Rework Cost Calculator
- Master Data Audit Sample Size Calculator
- Data Quality Sigma Level Calculator