Non-conformance and rework
Contain affected pieces, authorize the recovery plan and keep quality, quantity and cost evidence connected.
7 stages · 3 approvals
Roles and responsibilities
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Step 1Detect
Inspection NumberInspection TypeJobJob OperationIn Process
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Step 2Contain
Work CenterJobOperation NumberDescription
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Step 3Investigate
Inspection NumberInspection TypeJobJob OperationIn Process
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Step 4Authorize recovery
Job NumberJob TypeCustomerPartSplit
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Step 5Disposition
Work CenterJobOperation NumberDescription
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Step 6Release
Inspection NumberInspection TypeJobJob OperationIn Process
Process steps
Follow the process from start to finish. Select a step to see who acts and what changes.
Detect
Quality Inspector records the affected scope from a floor report, receiving issue, outside return, inspection failure or customer return. Operator and other operating roles report what they observed. The NCR names the actual lot, operation or receipt, quantity and revision; customer returns retain their original dispatch lineage.
Contain
Quality Inspector places the affected scope on hold and coordinates physical segregation. Shop Supervisor or Production Manager can also stop eligible operations within their authority. The held quantity cannot be issued onward or packed simply because an earlier acceptance exists; unaffected pieces remain separately identifiable.
Investigate
Quality Inspector records the cause, evidence and proposed technical disposition. Reinspection references the original inspection and the remaining affected pieces. It does not create another population of accepted output. Buyer supplies supplier evidence, and Production Manager assesses the practical recovery work.
Approval required
Authorize recovery
Production Manager authorizes feasible rework or transfer scope within their authority. Shop Owner decides new unrecovered or financial scope where required. The reviewed plan identifies cost, customer-demand allocation and required agreement. A remake covers the approved original shortfall rather than creating another sale.
Approval required
Disposition
Quality Inspector records the approved technical outcome for exact quantities. Rework creates distinct work; Scrap records terminal physical disposition; Remake assigns recovery demand; ReturnToSupplier preserves custody evidence. UseAsIs requires written customer acceptance of the applicable deviation. Customer-required evidence cannot be waived by a general owner note.
Approval required
Release
Quality Inspector verifies completion of the disposition and required reinspection before releasing affected pieces. Final acceptance must be independent of the production worker. Returned parts from a closed job use linked Rework, Remake or Adjustment work; closing the NCR cannot reopen the original ledger or erase its shipment.
Learn
Estimator reviews recurring causes with Production Manager and Shop Owner. Scrap and Rework distinguishes unique first-pass loss from repeated inspections and recovery effort. Proposed routing or estimating changes are reviewed for future work, leaving the closed job's original instructions and estimate intact.
Approvals and exception handling
3 approvals required in this process
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Authorize recovery
Production Manager or Shop Owner signs when required · disposition waits
ApprovalDecisions, JobTransfers, JobAllocations, Jobs -
Disposition
Quality Inspector signs · release waits
NonConformances, ProductionEvents, JobOperations, ScrapCostAllocations -
Release
Quality Inspector signs for quality release · learn waits
Inspections, ProductionLots, ApprovalDecisions, NonConformances - Split the affected cohort before assigning different dispositions. The same piece cannot be both accepted and scrapped or appear in two active lots.
- Scrap attribution allocates existing materialLabour cost for analysis. It does not post those costs again; genuinely new rework or replacement inputs create their own cost.
- A return records physical arrival separately from creditReplacement entitlement. Neither an invoice credit nor an NCR proves that goods are back in the shop.
- Work already movedConsumed or shipped needs a controlled successor or return path. A status reversal cannot recreate its original available quantity.
- Technical acceptanceCommercial authority remain separate. Required customer agreement and independent final quality review still apply in a small shop.
When the process needs attention
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reject
Detect
Quality Inspector records the affected scope from a floor report, receiving issue, outside return, inspection failure or customer return.
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hold
Contain
Quality Inspector places the affected scope on hold and coordinates physical segregation.
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shortage
Authorize recovery
A remake covers the approved original shortfall rather than creating another sale.
Records and postings
| Stage | Records | Effect |
|---|---|---|
| 1 Detect | NonConformancesInspectionsProductionLotsCustomerReturns | Record affected physical scope |
| 2 Contain | ProductionLotsJobOperationsJobs | Hold the affected work |
| 3 Investigate | NonConformancesInspectionsReceipts | Establish cause and proposed disposition |
| 4 Authorize recovery | ApprovalDecisionsJobTransfersJobAllocationsJobs | Authorize feasible recovery and financial scope |
| 5 Disposition | NonConformancesProductionEventsJobOperationsScrapCostAllocations | Apply the reviewed technical outcome |
| 6 Release | InspectionsProductionLotsApprovalDecisionsNonConformances | Release only verified eligible pieces |
| 7 Learn | PartRoutingsPartRoutingOperationsJobCostEntries | Propose future process improvements |
Process reports
All reportsOutside Processing Status
Each posted OutsideDispatches lot: sent, physically returned, accepted/rejected, still-outside and unresolved quantity, original/current promised instant and elapsed days. Partial returns do not mark the whole operation complete; LOT cost/billing basis and unknown promise remain explicit.
Job Cost Summary
Original release JobSnapshots and current approved per-type/operation estimate against signed posted JobCostEntries, with operational gross cost and balanced transfer effects separately identified. Include compensated originals plus negative legs once. Unknown/unposted amounts remain visible; no zero-margin calculation when sell price is zero.
Work Centre Load
Confirmed ScheduleSlots remaining occupied machine/work hours by named resource and week divided by actual available calendar hours, rolled up without multiplying machine count twice. Zero capacity shows unschedulable work, proposed slots shown separately; outside supplier spans are lead time, not internal capacity.
Late and At-Risk Jobs
Open active customer obligations against original and current approved due dates; estimate remaining path using confirmed resource capacity, material/inspection holds and outside promises. Show unknown duration/calendar as unresolved risk; this is a planning estimate, not a delivery guarantee.
Scrap and Rework
Unique first-pass input/good/scrap physical quantities from ProductionEvents by cause, job and work centre, with rejected/reworked units shown separately. Scrap rate uses scrapped first-pass units divided by original first-pass input; reinspections/rework cycles are not new input. Cost is ScrapCostAllocations plus genuinely incremental rework expense, with source overlaps eliminated, not an extra ledger charge.
Run by an agent
Agent support
An agent cannot turn preparation into a required human approval. Margin exceptions, controlled purchases, production release, ticket approval, quality decisions and job close follow their configured authority. Automatic policy paths must be explicitly defined; an agent role does not create a bypass. Access to a record does not permit changing a released traveler, spending reserved stock or rewriting a posted amount.
# Example after configuration
$ curl -fsSL https://www.erp.ai/skill.md | paste into your agent
› non-conformance and rework · detect on NonConformances, Inspections, ProductionLots, CustomerReturns
✓ Quality Inspector records the affected scope from a floor report, receiving issue, outside return, inspection failure or customer return.
› non-conformance and rework · contain on ProductionLots, JobOperations, Jobs
✓ Quality Inspector places the affected scope on hold and coordinates physical segregation.
› non-conformance and rework · investigate on NonConformances, Inspections, Receipts
✓ Quality Inspector records the cause, evidence and proposed technical disposition.
› non-conformance and rework · authorize recovery on ApprovalDecisions, JobTransfers, JobAllocations, Jobs
⏸ approval when required · waiting for the production manager or shop owner
# 3 more stages after approval: disposition, release, learn
Other processes
5 moreQuote to job
Turn the customer RFQ into a reviewed offer and a released job with the right drawing, traveler and material plan.
7 stages · 2 approvals
Release to ship
Move released work through production, reviewed time and quality checks into a traceable customer shipment.
9 stages · 3 approvals
Outside processing
Follow each lot through its supplier order, outbound custody, partial return and quality acceptance.
7 stages · 2 approvals
Change orders
Review changes against the work already done, authorize their cost and customer impact, and release a clear revised traveler.
6 stages · 1 approval
Job close
Reconcile completed work and remaining obligations, authorize the final cost review and preserve a useful benchmark for repeat quotes.
6 stages · 2 approvals