⏱️ SOP 07 — Hourly Production Check

SOP Name:         Hourly Production Check
Process Code:     HOURLY_PROD_CHECK_V1
Version:          V1
Owner:            Factory Supervisor
Applies To:       Factory Supervisor
Frequency:        Every production hour
Last Updated:     2026-06-25
Review Frequency: Monthly

1. Purpose

Catch quality issues early during production.

2. Who Is Responsible

Factory Supervisor — performs the hourly check and decides hold/continue.

3. When To Use This SOP

Once every production hour, throughout the production run.

4. Visual Process Flow

flowchart TD
A[Every hour] --> B[Select sample bricks]
B --> C[Check visual quality]
C --> D[Check stack count]
D --> E{Issue found?}
E -- Yes --> F[Hold batch / correct process]
E -- No --> G[Continue production]

5. Step-by-Step Visual SOP

Every hour, check sample bricks from current production. [PHOTO: Hourly sample]
Inspect cracks, corner break, surface and size.
Confirm stacking count.
Check if mix consistency has changed.
Stop and correct if defects increase.
Record the issue if any.

6. Do / Don't

✅ Do	❌ Don't
Check a real sample every hour	Skip hours when "things look fine"
Act the moment defects rise	Wait until end of day to react
Note rejection count	Leave defects unrecorded

7. Checklist

[ ] Hourly sample checked
[ ] No major cracks
[ ] Edge quality acceptable
[ ] Stack count correct
[ ] Mix consistency acceptable
[ ] Rejection count noted

8. Records To Update

🔵 Hourly check log
🔵 Batch record (rejection count)
🔵 Telegram alert if a batch is held

9. Escalation Rule

Inform Ram/Srinivasan if defects rise sharply within an hour or if the process must be stopped mid-run.

10. Common Mistakes

Skipping the check during busy hours.
Not noticing a gradual change in mix consistency.
Continuing despite an increasing reject count.

11. Improvement Suggestion

If you find a better way to do this process, add a comment below or submit an improvement request in the SOP Improvement Register.

Automation Readiness

Telegram command: /hourly
n8n workflow:     wf_hourly_check_v1
Odoo object:      quality.check
Approval role:    Factory Supervisor
Supabase table:   hourly_checks
Status:           Future automation