Feature · Quality Management
Quality management that closes the loop — and refuses to fake it
NCR, CAPA, NDE, ITP, audit — connected and enforced. Dispositions need a named sign-off, repairs need passing re-inspection, and a CAPA won't close without a documented root cause and verified effectiveness.
Gates, not reminders
The enforced loop
- 1
Finding → NCR
Any Critical or Major finding becomes a nonconformance with one tap — auto-numbered, photos attached, source inspection linked, severity carried over.
- 2
Disposition, signed
Dispositions are a controlled vocabulary, not free text. Use-As-Is and Repair require manager approval and a documented reason — stamped with a name and a timestamp.
- 3
Repair proves itself
A Repair or Rework NCR cannot close until a passing re-inspection or an accepted NDE examination — performed after the disposition — is linked to it.
- 4
CAPA closes only when closed
Closure is refused without a documented root cause and a verified, recorded effectiveness check — “Ineffective” can't be closed away. Owners, due dates, and reminders run until then.
- 5
Recurrence surveillance
If the same defect recurs on the same part within a year, the closed CAPA is flagged for recurrence and managers are alerted — a human rules on whether it was effective.
Even the refusals are records.
Every blocked attempt — a closure without evidence, a disposition without sign-off, a procedure pushed past its qualified envelope — is written to its own audit stream. The shortcut that didn't happen is still on the record.
Pick the right tool
Root cause analysis methods
5 Whys
Process and human-factor issues.
Fishbone
Multi-factor causes — Man, Method, Machine, Material, Measurement, Environment.
Fault Tree
Sequential and conditional failures — pressure vessels, control systems.
8D
Team-based, eight-discipline approach for recurring or customer-facing failures — containment through prevention.
Built in, not bolted on
Compliance depth that usually costs six figures
NDE / NDT Management
RT, UT, MT, PT and VT examinations — request, assign, record indications, accept/reject sign-off, tied to the weld map.
ITP & Hold Points
Inspection and Test Plans with hold, witness and review points — hold points hard-stop the traveler until signed off.
MDR / Turnover Data Books
The customer data book compiles itself — MTRs, WPS/PQR, welders, NDE, calibration — and names its own gaps instead of hiding them.
Immutable Audit Trail
A hash-chained, append-only record of every quality-critical change — who, what, before and after. Tampering breaks the chain loudly.
MRB & Quarantine
Material holds that actually block stock issuance, with formal MRB dispositions and sign-off — use-as-is and waivers require a documented reason.
Welder Continuity
Activity-based process continuity per ASME IX and AWS D1.1, tracked from the work itself — lapses flagged before they become findings.
Automotive-grade quality
SPC, PPAP, control plans, Cost of Quality, and RMA
Cost of Quality
Four-bucket Cost of Quality — prevention, appraisal, internal and external failure rolled up from NCRs, rework, scrap, and RMA returns. Quality in dollars.
SPC Charts
Real-time variable and attribute control charts with Western Electric rules, capability studies (Cpk/Ppk), and out-of-control gating.
Control Plans
AIAG-format control plans linked to PFMEA — RPN drives the recommended inspection frequency per characteristic.
FAI / PPAP
18-element PPAP submission packages, levels 1–5, with present-and-valid enforcement — alongside First Article Inspection.
RMA Workflow
Customer returns with traceability linkage — genealogy, original inspections, and prior NCRs per returned unit — through disposition and return cost capture.
The qualified envelope, checked live
WPS and PQR that check themselves against the record
- Guided pWPS → PQR → WPS authoring, with the envelope checked live as you type
- Out-of-envelope changes are blocked unless a named engineer acknowledges a re-qualification stamp — and the stamp prints on the document
- Code-table ranges derived from the test coupon as suggestions — edition-stamped (ASME IX-2021 and AWS D1.1:2020, as reproduced from cited sources) and informational until a human adopts them on the PQR
- Welder performance qualification: WPQ records with WQTR documents — scope and continuity stay separate axes, never collapsed into one flag
- Seeded base- and filler-metal libraries — P-numbers, F- and A-numbers, every system row citing its verification source
- A code-format WPS PDF generated from the structured record — qualification basis and stamps printed exactly as recorded
- Start from a paper WPS — extraction prefills the form for your review, field by field
- Welding process — GMAW within GMAW
- Base metal P-number — 1 within 1
- Thickness — max 32 mm above qualified 20 mm QW-403.8 / D1.1 Table 6.6
- Shielding gas — the PQR doesn't record this — verify manually
- Thickness (derived) — the 12 mm coupon derives 5–24 mm — derived per ASME BPVC IX-2021, as reproduced; informational until adopted on the PQR QW-451.1 (derived)
The same check runs as you type — and it's the same check that gates the record. Proven violations block unless a named engineer acknowledges a re-qualification stamp; violet advisories are suggestions and never block.
Your code, your CWI, verified
Code rules your CWI verified — every determination cites its clause
Flaggity ships no code content. Your CWI extracts rules from your own licensed edition of the standard and signs each one; a deterministic evaluator then checks every WPS against those verified rules. Where nothing has been verified, the answer is no_verified_rule — named, not guessed.
- Customer-verified rule packs — extracted from your licensed edition and individually signed by your credentialed CWI
- Deterministic determinations — every pass or fail cites the exact clause and the edition it was checked against
- no_verified_rule where nothing is proven — unverified variables are named, never assumed compliant
- Edition-aware — packs pin the edition your CWI verified, and an edition change flags affected determinations for re-review
Audits + evidence
Audit management
- Schedule internal, customer, and certification audits
- Per-clause finding tracker (ISO 9001 clauses pre-loaded)
- Evidence attachment — link inspections, NCRs, CAPAs
- Auto-generated audit packet PDF for the auditor
- Findings auto-create CAPAs with owner and due date
- Formal inspection certificates in four designs — default branded, minimal, bold, classic
Hold suppliers accountable
Supplier quality
- Supplier scorecard — quality, delivery, responsiveness
- SCAR (Supplier Corrective Action Request) workflow
- Score trend chart per supplier
- Auto-escalate when scores fall below threshold
- Incoming inspection records tied to supplier
- Receiving inspection — rejected material is quarantined into MRB automatically, with dispositions that require sign-off
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