Manufacturing: BOM, work orders, costing
Bills of materials, the three work-order types, costing, the production board and the production reports.
Quality Control app
Check every lot before it costs you — receipt to certificate.
Quality Control turns the documents you already post — purchase receipts, production runs, job work, transfers, deliveries and customer returns — into inspection lots. It samples them by AQL, keeps doubtful stock on hold until someone decides, and carries every failure through a non-conformance report and a corrective action. All inside TamilAccounting, on the same items, suppliers and stock as your books.
Manufacturers
Food & beverage
Pharma & chemicals
Textile mills
Engineering components
Job-work units
Awaiting decision6
First-pass yield94.2%
On hold1,240 kg
Cotton yarn · Supplier A1,200 conesSample 80
Grey fabric · Production4,800 mAccepted
Housing · Job worker B600 pcsRejected → NCR
Spice mix · Supplier C800 pktsSkip-lot
Without a quality system
Where poor quality quietly eats the margin
Most plants inspect — on clipboards, in spreadsheets and in the QC manager’s head. The checks happen; the control does not. These are the gaps we see most often.
Material used before it is passed
Raw material reaches the line the day it arrives. The test result comes back after it is already inside a batch.
Cost: a whole production run built on a bad lot.
Results that live on paper
Readings sit on clipboards, not against the receipt, the batch or the supplier. When a customer complains, finding the record takes days.
Cost: audits and complaints answered from memory.
Rejects that drift back into stock
A failed lot waits in a corner of the store with a chalk mark. On a night shift someone is short of material and uses it.
Cost: rejected goods shipped to a customer.
Same supplier, same defect
Nobody counts how often each supplier fails, so the same problem comes back every month — and the debit note is never raised.
Cost: full price paid for goods you rejected.
Gauges nobody calibrates
The vernier, the weighing scale and the moisture meter were calibrated “some time last year”. Readings from an out-of-date instrument prove nothing.
Cost: an audit finding — or a recall you cannot defend.
Fixes agreed, never checked
A corrective action is agreed in a meeting and forgotten. Nobody owns it, nobody dates it and nobody checks that it worked.
Cost: the same non-conformance raised again next quarter.
With Quality Control
One lot, from the gate to the decision
Quality runs on the documents you already post. Nothing is typed twice, and every step is recorded with who did it and when.
Document postedReceipt, production run, job work, transfer, delivery or return
Lot opensFor items whose quality settings ask for one, with an inspector and a due date
Stock blockedMoved to the inspection location until the decision, if the item says so
SampledAQL sample size — or 100%, a fixed quantity or a percentage
InspectedReadings against the specification, with the gauge used and defects counted
Usage decisionAccept, accept with deviation, accept part or reject
Hold & NCRRejected quantity held; the review board decides what happens to it
Loop closedCAPA fixes the root cause; the customer gets a certificate of analysis
How it works
Quality control built into the documents, not beside them
No second system to keep in step: inspections, holds and dispositions work on your own items, suppliers, batches and stock locations.
Inspection lots
Lots that open themselves when goods move
Each item — or a whole stock category — says which documents need inspecting. Post the purchase receipt, the production run or the job work receipt, and a lot opens for each of those lines with its batch, sample size and due date set, assigned to your default inspector.
- An inspection plan per item: measured checks with limits, pass / fail checks and defect counts
- Separate checks for incoming goods, production and outgoing deliveries
- Each reading keeps the specification it was taken against, and the gauge used
- A clean pass can be accepted automatically; anything else waits for a decision
Lot1,200
Sample80
ResultHold
Count (Ne) 29.5–30.530.2In limits
Strength (CSP) min 2,1002,180In limits
Moisture % max 8.59.1Out of limits
Gauge · Moisture meter 02Due 14 NovCalibrated
AQL sampling
Sample sizes from the standard — and from each supplier’s record
Choose AQL sampling and the lot size picks the sample: ISO 2859-1 single sampling, normal inspection, with the acceptance and rejection numbers for major and minor defects. Critical defects are always accepted at zero.
- General inspection levels I, II and III, and special levels S-1 to S-4
- Or inspect 100%, a fixed quantity, or a percentage of the lot
- Skip-lot: after a run of accepted lots from a supplier, only one lot in so many is inspected
- One rejected lot sends that supplier’s next lots to 100% inspection
Lot size 1,200 · Level IILetter JSample 80
Critical defectsAc 0 / Re 1Zero
Major defects · AQL 1.0Ac 2 / Re 3Found 1
Minor defects · AQL 4.0Ac 7 / Re 8Found 3
Supplier history8 accepted in a rowSkip-lot next
Holds & NCRs
Rejected stock stays put until someone decides
The usage decision moves the accepted quantity back into use and keeps the rest on a quality hold. A hold moves only when somebody acts on it: quarantine, release, scrap or reject. A rejected lot can raise its non-conformance report automatically.
- Review-board dispositions: use as is, rework, scrap, return to supplier, sort or downgrade
- The disposition is carried out on the hold — scrap writes the stock off, use as is releases it
- Return to supplier on bought-in goods opens the supplier credit note already filled in
- Scrap, rework and other costs add up to the cost of poor quality
Held600 pcs
SeverityMajor
Cost₹14,400
Defect · Bore oversize42 pcsMajor
ContainmentQuarantinedOn hold
DispositionReworkRe-inspect
EscalatedCAPA-0031Root cause
CAPA
Corrective actions that are closed only when they worked
A CAPA takes a problem — one or more NCRs, a customer complaint or an audit finding — to its root cause, puts owned and dated actions against it, and closes only after a later check shows the fix held.
- Open → root cause → actions → verification → closed
- Root cause by 5 Whys, fishbone or 8D
- A fix that did not work sends the CAPA back for more actions
- Closing an effective CAPA closes the NCRs it answered
Root cause · 5 WhysWorn boring toolRecorded
Replace tool, check settingJob worker BDone
Add bore check to first-offQC engineerDone
Tool-life check every lotDue 20 OctOpen
Effectiveness checkNext 3 lotsVerification
More in the app
Everything a quality manager is asked for
The records an auditor, a customer or your own management will want to see — kept as you work, not assembled the night before.
SPC & capability
Control charts for every measured check — X-bar / R or individuals — with out-of-control points flagged, and Cp, Cpk, Pp and Ppk worked out from the readings.
Gauge calibration
Each gauge has a calibration interval and a history. Gauges due within two weeks are flagged, and a gauge past its date can be refused for readings.
Certificates of analysis
An inspected delivery prints its certificate from its own view — every check with its specification, the result and the conformity — ready to send with the goods.
Supplier scorecards
Every supplier and job worker scored out of 100 on what they delivered, plus an approved supplier list with a status and a next review date for each.
E-signatures & audit trail
Switch on electronic signatures and users re-enter their password to take a usage decision, disposition an NCR or close a CAPA. Every step is logged.
Quality overview
First-pass yield by week, the defects found most often, lots needing attention, open holds, NCRs and CAPAs, and the cost of poor quality for the period.
Daily reminders
Overdue lots go to their inspector, late NCRs and CAPA actions to their owners, and gauges coming due to the quality manager — in the app and by email.
Quality on the item
The item screen shows its checks, its last result, open lots and NCRs and the quantity on hold. Purchases and Manufacturing each get a tab of their own inspections.
Watch it in action
See the production flow quality plugs into
Production runs and job work receipts are two of the documents that open inspection lots. These walkthroughs show those flows on a demo company — Quality Control adds its checks on top of them.
Job work: send it out, get it back costed
Material goes to the job worker on a challan, stays your stock, and comes back with the charge added.
Quick takes · under a minute or two
Who it is for
Built for businesses that cannot ship a bad lot
Any business that receives, makes or ships goods against a specification. These are the ones that feel it most.
01
Manufacturers
Incoming checks on raw material, in-process checks on every production run, and an outgoing check before the delivery leaves the gate.
02
Food & beverage
Raw material held until it passes, inspections traced by batch, and a certificate of analysis for the customer with each inspected delivery.
03
Pharma & chemicals
Electronic signatures on decisions, a full audit trail, calibrated instruments and CAPAs closed only after an effectiveness check.
04
Textile mills
Yarn checked as it arrives, fabric inspected off the looms, and cloth coming back from the dyer inspected before it is accepted.
05
Engineering components
Measured dimensions against tolerances, gauges with a calibration history, and the Cpk figures your customers ask for in their audits.
06
Businesses using job workers
Every job work receipt inspected, rejects held against the job worker, and a scorecard that shows which job workers deliver right first time.
Why businesses stay
Bring your data. We’ll keep it right — and keep making it better.
Switching software is the hard part. We help you move, keep your records sound, and keep improving the system with you.
Data migration & opening balances
Move across from Tally, Zoho, QuickBooks, Xero, Sage 50 or SMACC, or from Excel templates for items, customers, suppliers, employees, chart of accounts and opening balances. You preview every row before it is saved — and our team helps you through it.
Your data, kept right
Your database is backed up three times a day — every 8 hours — and your files are backed up too. Each company keeps its own separate database; roles decide who can see, enter, approve or void; every change is on the audit trail; and everything exports to Excel or PDF whenever you want it.
Always improving, with you
We follow up regularly with the businesses that use it, and their requests become features. Updates arrive on your account automatically — nothing to download or reinstall.
Connected to what comes next
GST e-invoice and e-way bill, ZATCA, WooCommerce, WhatsApp, biometric devices, online payment gateways, mobile apps and an AI assistant — and new connections are added as the market moves.
FAQ
Quality Control: common questions
Purchase receipts, production runs and job work receipts, location transfers (inspected where they arrive), sales deliveries (before they leave) and customer returns. Lots open on their own when these are posted, for the items or stock categories whose quality settings ask for it — and any of these documents can also be inspected from its own view.
Yes, for items you set to block stock. As the receipt is posted, the quantity is moved into an inspection location by a normal stock transfer. The usage decision moves the accepted quantity back and keeps the rest on a quality hold, which moves only when someone quarantines, releases, scraps or rejects it. A delivery has already left stock, so a hold on one records the problem for follow-up instead.
Quality Control keeps no ledger of its own. Blocking and quarantine are ordinary stock transfers. Scrapping a hold posts an ordinary inventory adjustment, so the write-off reaches the ledger at the item’s cost. Returning bought-in goods opens a supplier credit note already filled in for that supplier — against its invoice when there is one. Each NCR keeps its scrap, rework and other costs, which add up to the cost of poor quality.
Inspecting, managing holds, taking usage decisions and dispositions, NCRs, CAPAs, gauges, inspection plans and reports are separate permissions, so each can be given to the right role. With electronic signatures switched on, a decision, a disposition or a CAPA closure needs the user to re-enter their password, and the audit trail marks the step as signed.
AQL sampling follows ISO 2859-1 single sampling at normal inspection, with general levels I to III and special levels S-1 to S-4, and critical defects accepted at zero. Items that are not sampled by AQL can be inspected 100%, by a fixed quantity or by a percentage. Skip-lot and tightened inspection follow each supplier’s record per item.
Yes. Once a delivery has been inspected, its view offers a Certificate of Analysis listing each check with its specification, the result and the conformity. A certificate can also be printed for a single inspection.
Put quality on the same books as your stock.
Start free with your own items and suppliers — and add inspections, holds, NCRs and CAPA when you are ready.