DIGITAL QUALITY CONTROL FOR LEADING BIKE MANUFACTURER

The factory’s quality control system was spread out across paper forms, spreadsheets, and disconnected processes. Defects were often detected too late, making it difficult to trace their origins. Time was wasted manually duplicating data, causing delays and errors. The client needed a unified system where quality information seamlessly follows the product throughout every production stage, preventing loss and miscommunication between teams.

We developed a modular web application that streamlines the entire quality control process, making it faster and easier to manage. With a single login, factory workers access only their relevant modules - goods receipt, product check, auditing, repair, or painting. The system automatically opens the correct module based on each user’s role, eliminating extra clicks and confusion.

Key Modules

Goods Receipt Control

Upon truck arrival, a pre-loaded invoice-based checklist displays incoming goods status with color codes: white (unchecked), grey (no issues), and red (defect found). Defects can be documented with photos and comments and instantly reported digitally to suppliers, replacing inefficient email chains.

Line Inspection

Workers scan their workstation barcode, ensuring they log into the correct station. Scanning the production order loads a tailored checklist per product or customer template. Forms reset automatically after each scan, keeping workers in rhythm without typing.

Product Auditing (AQL)

Random batch audits include up to ten inspection steps. Critical defects can flag the entire batch, which is controlled by users with permissions. Each question has comment boxes for context beyond scores.

Repair Handling

Failed checks are automatically sent to the repair module. When a worker opens the repair log, a timer starts recording the actual Time to Repair (TTR). This helps management pinpoint bottlenecks and adjust resources. If a defect can’t be fixed, the item is marked “unrepairable,” and it’s automatically removed from production quotas.

Painting

Different defect types (surface, paint, mechanical, sticker) are tracked depending on the phase - Prep or Paint. Operators see tailored questions per stage and can undo or edit the last entry if needed.

Factory-Friendly Experience

• Color-coded statuses replace complex Excel filters, enabling quick issue spotting even by new staff.
• Scan-and-go interface minimizes typing, enhancing speed and cleanliness.
• Photo evidence ensures suppliers and engineers work with verified facts, not assumptions.