Overview

First-Off Inspection ensures that the first component produced during setup is approved before the operator can begin production cycle time. This requirement is configured at operation level within a process plan and uses the standard Job Order process. A separate first-off job is not required.

This article covers both Desktop RedAnt and Data Collection. Users configuring first-off inspections will need permission to edit process plans and inspection groups.

Setting Up Inspection Groups

Inspection groups define which employees are authorised to approve first-off inspections.

Navigation:
Maintenance > Employees > Setup

Create an Inspection Group

1. Under Inspection Groups, create a new group.
2. Give the group a meaningful name, such as Milling Inspection or Final Inspection.

Add Authorised Inspectors

1. Open Inspection Employees.
2. Select the inspection group.
3. Add each authorised employee number to the group.
4. Verify all required employees have been added before using the group on an operation.

Requiring First-Off Inspection on an Operation

Navigation:
Process Plan > Select Operation > Quality

Enable First-Off Inspection

1. Open the relevant process plan from:

   • Job Orders
   • Drawing/Register
   • Quotation

2. Select the required operation.

3. In Quality Control:

   • Tick First Off Inspection Required
   • Select the appropriate inspection group

Note: A valid inspection group must be selected before the Quality Control window can be closed.

Add Inspection Instructions (Optional)

If required:

1. Use Inspection Document to attach inspection procedures or instructions.
2. Close the Quality Control window to save.
3. Reopen the window to confirm the settings have been applied correctly.

Important: Process Plan Scope

First-off settings belong to the register process plan, even when opened from a Job Order.

Before making changes:

• Check whether other jobs share the same plan.
• For released jobs, ensure the planner verifies first-off requirements before production begins.

Setting First-Off Inspection as a Work Centre Default

Navigation:
Work Centres

The First Off Required option allows a work centre to automatically apply first-off inspection requirements when used in a process plan.

How It Works

• When enabled, new operations using that work centre will default to requiring first-off inspection.
• Planners can remove the requirement on individual operations if needed.
• The inspection group must still be reviewed and assigned on each operation.

Updating Existing Operations

If prompted:

"Set First Off for ALL planning operations?"

Select Yes only if every existing operation using that work centre should be updated.

Approving First-Off Inspection on the Shop Floor

Important: Always complete the physical inspection before recording approval within RedAnt.

Approving at a Data Collection Terminal

1. Complete Setup

1. Book setup time against the correct:

   • Job
   • Operation
   • Work Centre

2. Produce the first component.

3. Arrange inspection with an authorised member of the selected inspection group.

2. Respond to the First-Off Prompt

When setup is completed, RedAnt may display:

Accept First Off?

If an operator attempts to start cycle time without approval, RedAnt will display a warning indicating that first-off approval is required before production can begin.

3. Record Approval

Once the component has passed inspection:

1. Select Yes.
2. Choose the approving inspector from the list.
3. If prompted, the inspector should enter their own PIN.
4. Confirm the approval.

4. Begin Production

Complete any remaining booking prompts and verify that:

• Cycle time is running.
• The correct job, operation, and work centre are displayed.

If the component fails inspection:

1. Select No.
2. Resolve the issue.
3. Repeat the inspection process.

Sending a Part to the Inspection Queue

Some sites use a dedicated inspection work centre and inspection queue.

1. Move the Part to Inspection

At the first-off prompt:

1. Select Move To Inspection.
2. Choose an inspector from the available inspection group.

The selected inspector must be clocked in before the transfer can occur.

2. Confirm the Transfer

RedAnt will:

• End the operator's setup booking.
• Create an inspection booking for the selected inspector.

The physical transfer of the part should be carried out using your site's normal procedures.

3. Open the Inspection Queue

The inspector should navigate to:

Inspection > Jobs Pending

The window displayed is Jobs Pending Inspection.

Before proceeding, verify the correct job and operation have been selected.

4. Pass or Reject the Inspection

After inspecting the component:

1. Select Pass or Reject.
2. Confirm the action.

The desktop login performing the action must be associated with a valid employee record.

If Passed

RedAnt will:

• Record first-off approval.
• End the inspection booking.
• Automatically start cycle time for the original operator.

The operator should be informed that production has started.

If Rejected

RedAnt will:

• End the inspection booking.
• Restart setup time for the original operator.

The operator should be informed that the component failed inspection and that corrective action is required before another inspection attempt.

Important: Pass and Reject actions immediately affect live time bookings. Ensure both the operator and inspector are aware of the decision before either starts another booking.

Verifying First-Off Approval

After approval, confirm that the inspection has been recorded correctly.

Review the Inspection Record

1. Open Information / Job Enquiry.
2. Select First Off.
3. Verify that approval has been recorded against the correct operation.

Verify Production Time

Confirm that:

• Accepted parts have moved into cycle time.
• Rejected parts have returned to setup time.
• The correct job, operation, and work centre are active.

Retain Inspection Records

Any company-required documentation should still be completed, including:

• Measurement sheets
• Inspection reports
• Quality records

First-off approval in RedAnt does not replace physical inspection evidence.

Troubleshooting

"Enter a valid first off group"

Cause: No inspection group has been selected.

Resolution:

• Return to Quality Control.
• Select a valid inspection group.
• If no suitable group exists, create one in Maintenance > Employees > Setup.

Inspector Not Available in the List

Cause: The inspector is not a member of the selected inspection group.

Resolution:

• Check which group is assigned to the operation.
• Verify the employee is assigned to that group.
• Confirm their employee record is active and correct.

"Inspector NOT Clocked In!"

Cause: The inspector has not clocked in.

Resolution:

• Ask the inspector to clock in before attempting approval or transfer.

"First off must be approved before starting the cycle"

Cause: Production is attempting to start before inspection approval.

Resolution:

• Complete the first-off inspection.
• Record approval using an authorised inspector.

Cycle time will remain blocked until approval is recorded.

"First off was not accepted on this work centre"

Cause: The operation may be running on a different work centre than the one originally approved.

Resolution:

• Confirm the correct machine was selected.
• Check whether the production plan is locked.
• Ask the planner to review any legitimate machine changes before continuing.

"No valid employee is associated with your login ID"

Cause: The Windows/Desktop login is not linked to an employee record.

Resolution:

• Ask an administrator to associate the login ID with the correct employee record.

Inspection queue approvals cannot be completed without this link.

First-Off Prompt Is Missing

Possible Causes:

• Plan is locked.
• User lacks editing permissions.
• Incorrect process plan is in use.
• First-off inspection is not enabled for the operation.
• First-off approval has already been completed.

Resolution:

• Ask the planner to verify the operation settings.
• Review the First Off tab in Job Enquiry to determine whether approval is already recorded.

First-Off vs In-Process Inspection

These are separate quality control functions and should not be confused.

Each setting has its own inspection group and configuration options. Configure them independently according to the quality requirements of the operation.