In-Process Quality Check Checklist [FREE PDF]

In-process quality checks are a foundational requirement of ISO 9001:2015 Clause 8.5.1, which mandates that organizations implement planned activities to verify that process outputs meet defined acceptance criteria at appropriate stages of production. These checks, when performed systematically, enable early detection of process drift, reduce cost of poor quality (COPQ), and support the Six Sigma DMAIC Control phase by maintaining processes within statistical control limits. This checklist provi

  • Industry: Manufacturing QA
  • Frequency: Daily
  • Estimated Time: 25-40 minutes
  • Role: QA Engineer
  • Total Items: 35
  • Compliance: ISO 9001:2015 Clause 8.5.1 - Control of Production and Service Provision, IATF 16949:2016 Clause 8.6.1 - Release of Products and Services - Supplemental, AS9100 Rev D Clause 8.5.1.1 - Control of Production and Service Provision, ISO 9001:2015 Clause 9.1 - Monitoring, Measurement, Analysis and Evaluation, ASTM E2587 - Standard Practice for Use of Control Charts in Statistical Process Control

Process Setup & First Article Verification

Verify that the production process is set up correctly with approved tooling, equipment, and process parameters before or at the start of production run.

  • Has a First Article Inspection (FAI) or first-off check been completed and approved prior to production run start?
  • Are all tooling items (dies, fixtures, jigs, cutting tools) at the correct revision level and in good condition?
  • Are process parameters (speed, feed, temperature, pressure, torque) set to values specified in the work instruction or control plan?
  • Is the approved Work Instruction (WI) or Standard Operating Procedure (SOP) available and being followed at the workstation?
  • Is the machine, equipment, or process within its preventive maintenance schedule with no outstanding maintenance holds?

In-Process Dimensional Verification

Perform dimensional checks on parts produced during the current run to confirm critical and significant characteristics remain within specification.

  • Are critical characteristics (identified on the control plan) being measured at the required frequency?
  • Are all measured critical dimensions within tolerance per the engineering drawing or specification?
  • Are measurement instruments used for in-process checks calibrated, tagged, and within calibration due date?
  • Is Statistical Process Control (SPC) data being collected and plotted for critical characteristics if required by the control plan?
  • Are SPC control charts showing processes in statistical control (no out-of-control signals per Western Electric rules)?
  • Please record the measured values of up to three critical characteristics from the most recent sample measured?

Visual & Workmanship Inspection

Inspect in-process parts for visual defects, surface anomalies, and workmanship non-conformances against approved visual standards.

  • Are parts free from visual defects including cracks, voids, inclusions, burrs, or surface contamination?
  • Is an approved visual workmanship standard or limit sample available and being referenced at the inspection station?
  • Are part markings, engravings, stamps, or identification features correctly applied, legible, and per specification?
  • Are assembly orientations, component placements, or sub-assembly joins correct and per the work instruction?
  • Please capture a photo of representative in-process parts showing current workmanship quality?

Process Parameter Monitoring

Verify that key process variables are being monitored, recorded, and remain within defined control limits throughout the production run.

  • Are all critical process parameters currently operating within the specified control limits defined in the Control Plan?
  • Is process temperature being monitored and within the specified range for any thermal processes (welding, curing, heat treating)?
  • What is the current measured process temperature for applicable thermal operations?
  • Is process data being logged in real-time or at specified intervals per the monitoring and measurement plan?
  • Have any process alarms or out-of-control conditions occurred since the last inspection point?

Non-Conforming Product Identification & Control

Ensure non-conforming in-process parts are immediately identified, segregated, and controlled to prevent inadvertent use or advancement to the next process stage.

  • Are all identified non-conforming parts physically segregated from conforming parts and clearly labeled with red rejection tags?
  • Has a Non-Conformance Report (NCR) or internal rejection tag been initiated for each non-conforming part or batch?
  • What is the current in-process defect rate or quantity of non-conforming parts identified during this production run?
  • Has the root cause of any identified non-conformance been determined and a corrective action initiated?
  • Has production been stopped (stop-and-fix authority exercised) if non-conformance rate exceeds the control plan threshold?

Operator Competency & Training Verification

Confirm that production and inspection personnel have the required competency, training, and certifications to perform their assigned tasks.

  • Are all operators on the current shift trained and certified to the work instruction for this operation?
  • Are operators performing any special processes (welding, NDT, soldering) currently certified per the applicable specification?
  • Are operators aware of the quality alert, reaction plan, or escalation procedure if a defect is detected?
  • Is operator performance data (error rate, quality output) being tracked and reviewed as part of the quality system?

Continuous Improvement & Corrective Actions

Review open corrective actions, process improvement initiatives, and verify that Six Sigma or Lean actions from previous inspections are progressing.

  • Are all open corrective actions from previous in-process inspection findings being actively tracked and addressed?
  • Are Lean or Six Sigma improvement projects (DMAIC, Kaizen) in progress for this process with measurable targets defined?
  • Has process capability (Cpk) been calculated for critical characteristics and is Cpk ≥ 1.33 or per customer requirement?
  • Please summarize any additional observations, improvement opportunities, or follow-up actions identified during this in-process inspection?
  • Please capture a photo of the SPC chart, process parameter display, or overall workstation condition at time of inspection?

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Why Use This In-Process Quality Check Checklist [FREE PDF]?

This in-process quality check checklist [free pdf] helps manufacturing qa teams maintain compliance and operational excellence. Designed for qa engineer professionals, this checklist covers 35 critical inspection points across 7 sections. Recommended frequency: daily.

Ensures compliance with ISO 9001:2015 Clause 8.5.1 - Control of Production and Service Provision, IATF 16949:2016 Clause 8.6.1 - Release of Products and Services - Supplemental, AS9100 Rev D Clause 8.5.1.1 - Control of Production and Service Provision, ISO 9001:2015 Clause 9.1 - Monitoring, Measurement, Analysis and Evaluation, ASTM E2587 - Standard Practice for Use of Control Charts in Statistical Process Control. Regulatory-aligned for audit readiness and inspection documentation.

Frequently Asked Questions

What does the In-Process Quality Check Checklist [FREE PDF] cover?

This checklist covers 35 inspection items across 7 sections: Process Setup & First Article Verification, In-Process Dimensional Verification, Visual & Workmanship Inspection, Process Parameter Monitoring, Non-Conforming Product Identification & Control, Operator Competency & Training Verification, Continuous Improvement & Corrective Actions. It is designed for manufacturing qa operations and compliance.

How often should this checklist be completed?

This checklist should be completed daily. Each completion takes approximately 25-40 minutes.

Who should use this In-Process Quality Check Checklist [FREE PDF]?

This checklist is designed for QA Engineer professionals in the manufacturing qa industry. It can be used for self-assessments, team audits, and regulatory compliance documentation.

Can I download this checklist as a PDF?

Yes, this checklist is available as a free PDF download. You can also use it digitally in the POPProbe mobile app for real-time data capture, photo documentation, and automatic reporting.

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