Accurately capture all job identification and client specification details to ensure complete traceability throughout the quality assurance process.
Job Order ID
Client Name
Client Product Code
Packaging Type Classification
Folding Carton
Flexible Packaging (Film/Foil)
Pressure-Sensitive Labels
Corrugated Board
Rigid Box
Wrap-Around Labels
Other Specialty Packaging
Describe specialty packaging type:
Press Machine ID
Press-01 Heidelberg XL 106
Press-02 KBA Rapida 106
Press-03 Komori Lithrone G840
Press-04 Manroland 700
Press-05 RMGT 920
Press-06 HP Indigo 12000
Press Operator Full Name
Assistant Operator Name (if applicable)
Production Shift
Day Shift (06:00-14:00)
Evening Shift (14:00-22:00)
Night Shift (22:00-06:00)
Inspection Start Date & Time
Inspection End Date & Time
Total Order Quantity (units)
Sample Inspection Size (units measured)
Does this job have special client requirements beyond standard specifications?
Detail all special client requirements:
Is this a rush or priority order?
Original promised delivery date
Document all color measurements using spectrophotometer readings. Delta E values must be recorded for each key measurement position across the printed sheet to identify spectral deviations from the approved standard.
Target Color Standard Reference
Pantone Coated Guide
Pantone Uncoated Guide
Custom Client-Provided Sample
Process CMYK ISO 12647-2
Extended Gamut (OGV/CMYK+)
Brand-Specific Color Atlas
Custom Sample ID/Reference
Ink Type Used
Conventional Sheetfed Ink
UV Curable Ink
Water-Based Ink
Soy-Based Eco Ink
LED UV Ink
Hybrid UV
Ink Batch/Lot Number
Ink Viscosity Reading (seconds, Zahn Cup)
Spectrophotometer Model & Serial
Spectrophotometer Last Calibration Date
Detailed Color Measurement Log Across Sheet Positions
Measurement Position | Target L*a*b* Values | Actual L*a*b* Values | Calculated Delta E | Within Tolerance? | Corrective Action Taken if Any | ||
|---|---|---|---|---|---|---|---|
A | B | C | D | E | F | ||
1 | Leading Edge Left | L:56.2 a:32.1 b:-8.4 | L:56.8 a:31.9 b:-8.2 | 0.85 | Yes | None required | |
2 | Center Position | L:56.2 a:32.1 b:-8.4 | L:57.1 a:32.5 b:-8.0 | 1.12 | Yes | Slight density increase | |
3 | Trailing Edge Right | L:56.2 a:32.1 b:-8.4 | L:58.3 a:33.2 b:-7.5 | 2.67 | Ink key adjustment +2 units | ||
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Overall Delta E Status Classification
Within Tolerance (Delta E ≤ 2.0)
Minor Deviation (Delta E 2.1-3.0)
Major Deviation (Delta E 3.1-5.0)
Critical Failure (Delta E > 5.0)
Describe the minor deviation and its potential impact:
Detail the major deviation and immediate containment actions:
Explain critical failure and full stop procedure initiated:
Was an ink formulation or density adjustment made to correct color variance?
Ink Adjustment Details
Ink Station/Unit | Parameter Adjusted | Original Value | Adjusted Value | Adjustment Time (minutes) | ||
|---|---|---|---|---|---|---|
A | B | C | D | E | ||
1 | Cyan Unit | Density | 1.35 | 1.42 | 8 | |
2 | Magenta Unit | Ink Key Opening | 45% | 48% | 5 | |
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Total Number of Color Readings Taken During Run
Industry Tolerance Standard Applied (e.g., ISO, G7, client-specific)
Thoroughly inspect and record substrate material properties, focusing on paper weight variance, caliper consistency, surface quality, and any material defects that could impact print quality or structural integrity.
Substrate Material Type
Coated Gloss Paper/Board
Coated Matte Paper/Board
Uncoated Offset Paper
Textured/Feltmarked Paper
Synthetic Polymer Film
Metalized Substrate
Specialty Material (Foil, Holographic, etc.)
Substrate Brand/Manufacturer
Substrate Batch/Lot Number
Nominal Substrate Weight (g/m²)
Measured Weight Position 1 - Leading Edge (g/m²)
Measured Weight Position 2 - Center (g/m²)
Measured Weight Position 3 - Trailing Edge (g/m²)
Average Measured Weight (g/m²)
Weight Variance Percentage (%)
Weight Variance Status
Within Specification (≤ ±5%)
Minor Variance (±5.1-8%)
Major Variance (±8.1-12%)
Critical Variance (> ±12%)
Was the material batch rejected due to weight variance?
Provide detailed rejection justification and supplier notification actions:
Was the material batch rejected due to weight variance?
Provide detailed rejection justification and supplier notification actions:
Was the material batch rejected due to weight variance?
Provide detailed rejection justification and supplier notification actions:
Substrate Defects Observed During Inspection
None - Material is Clean
Edge Damage or Crushed Corners
Visible Wrinkles or Creases
Caliper/Thickness Variation
Surface Contamination (dust, oil, etc.)
Excessive Moisture Content
Coating Defects (mottling, streaks)
Color Shade Variation
Other Defect
Substrate Moisture Content Reading (%)
Surface Energy/Dynes Level (dynes/cm)
Was substrate stored under proper environmental conditions (temperature/humidity)?
Describe storage condition issues and potential impact on material:
Additional Material Quality Observations:
Document all press speed modifications and waste generation data. Calculate waste percentages and identify root causes to support continuous improvement initiatives.
Standard Rated Press Speed (sheets/hour or meters/min)
Actual Average Press Speed During Production Run
Was the press speed adjusted from standard settings during this run?
Primary Reason for Speed Adjustment
Color Stabilization & Density Control
Registration/Alignment Issues
Substrate Feed or Tension Problems
Heavy Ink Coverage Requirements
Operator Discretion for Quality
Mechanical or Technical Limitation
Material Defect Mitigation
Final Press Speed After Adjustments
Total Production Time Lost Due to Adjustments (minutes)
Total Material Waste Generated (kg)
Waste as Percentage of Total Material Used (%)
Waste Breakdown by Category
Waste Type Category | Quantity (kg) | Root Cause Code | Preventable? | ||
|---|---|---|---|---|---|
A | B | C | D | ||
1 | Setup/Make-ready Waste | 12.3 | S1-Color Matching | Yes | |
2 | Running Waste - Color | 8.7 | R2-Delta E Deviation | ||
3 | Running Waste - Substrate | 15.2 | R4-Material Defect | ||
4 | Downtime Waste | 9.3 | D1-Press Stop | Yes | |
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Waste Reduction Actions Implemented
No Action Taken
Press Speed Optimization
Ink Formulation Adjustment
Material Pre-inspection/Sorting
Operator Skills Retraining
Preventive Maintenance
Process Parameter Fine-Tuning
Other Action
Estimated Cost of Waste Material (in your currency)
Does any portion of this production run require rework?
Quantity Requiring Rework (units)
Root Cause Analysis Summary for Waste Generation:
Final quality review and authorization by Print Production Director. All deviations must be reviewed and approved before job release to finishing or shipping.
Print Production Director Name
Final Quality Review Decision
Approved as Is - Meets All Standards
Approved with Minor Deviation Notes - Release to Finishing
Conditionally Approved - Requires Rework Before Release
Rejected - Quality Failure - Do Not Proceed
Quarantined - Hold for Further Technical Review
Detailed Rework Instructions and Quality Gates:
Rejection Justification and Disposition Plan:
Reason for Quarantine and Required Technical Review:
Director's Overall Assessment and Comments:
Director Digital Signature
Director Approval Date & Time
Overall Production Run Quality Rating (1=Poor to 5=Excellent)
Has the client been formally notified of any deviations or quality issues?
Client Notification Method
Email Notification
Phone Call
Formal Quality Deviation Report
Client Portal Update
Video Conference
Should this QA intake form trigger a formal Corrective Action Preventive Action (CAPA) investigation?
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