🔴🟡🟢 SOP 09 — Visual QC / Hold / Reject

SOP Name:         Visual QC / Hold / Reject
Process Code:     VISUAL_QC_REJECT_V1
Version:          V1
Owner:            Factory Supervisor
Applies To:       Factory Supervisor, QC, Labour Team
Frequency:        Every batch and before dispatch
Last Updated:     2026-06-25
Review Frequency: Monthly

1. Purpose

Separate approved, hold and rejected bricks clearly.

2. Who Is Responsible

Factory Supervisor / QC — categorises bricks and records reasons.
Labour team — moves bricks to the correct area.

3. When To Use This SOP

On every batch after stacking, and again before dispatch approval.

4. Visual Process Flow

flowchart TD
A[Inspect bricks] --> B{Quality status?}
B -- Good --> C[Approved stock]
B -- Doubtful --> D[Hold area]
B -- Bad --> E[Reject area]
D --> F[Management/QC decision]
E --> G[Record rejection reason]

5. Quality Categories

🟢 Approved — good shape, no cracks, acceptable finish, correct size, ready for curing/dispatch.
🟡 Hold — doubtful quality, under-cured, moisture issue; needs management/QC decision.
🔴 Reject — broken, cracked, poor shape, wrong mix, poor compaction or not saleable.

[PHOTO: Approved] [PHOTO: Hold] [PHOTO: Reject]

Defect Reasons

Corner break        Interlock mismatch     Surface powdering
Crack               Too wet mix            Colour inconsistency
Poor compaction     Too dry mix            Handling damage
Wrong size

6. Do / Don't

✅ Do	❌ Don't
Separate approved / hold / reject physically	Leave reject bricks in approved stacks
Record the reason for every reject	Reject without noting why
Photograph major defects	Decide "hold" without escalating

7. Checklist

[ ] Batch inspected
[ ] Approved stock separated
[ ] Hold stock marked
[ ] Reject stock moved to reject area
[ ] Reason recorded
[ ] Photo taken for major defects

8. Records To Update

🔵 QC Hold/Reject register (reason + quantity)
🔵 Batch record
🔵 Telegram alert on high rejection

9. Escalation Rule

Inform Ram/Srinivasan if rejection is unusually high or if a full batch is doubtful.

10. Common Mistakes

Mixing a few rejects back into approved stock.
Recording a reject count without the reason.
Leaving "hold" bricks undecided for days.

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: /qc
n8n workflow:     wf_visual_qc_v1
Odoo object:      quality.check / stock.scrap
Approval role:    Factory Supervisor + QC
Supabase table:   qc_hold_reject
Status:           Future automation