This section captures essential job and client information to establish traceability and context for the reported quality deviation. Accurate metadata ensures proper routing of quality issues and enables trend analysis across clients, brands, and product lines.
Job Order ID
Client Organization Name
Brand Name
Product Line or SKU
Packaging Type
Folding Carton
Flexible Pouch
Corrugated Box
Label Stock
Shrink Sleeve
Rigid Box
Blister Pack
Other
Primary Print Process
Flexography
Offset Lithography
Gravure
Digital Inkjet
Screen Printing
Combination Process
Total Order Quantity (in thousands of units)
Press Unit Identifier
Production Shift
First Shift (Day)
Second Shift (Evening)
Third Shift (Night)
Weekend Shift
Press Operator Name or Badge ID
Date and Time of Deviation Detection
Current Job Status at Time of Detection
In Production
Setup/Make-Ready
Approval Sample Stage
Rerun in Progress
Winding/Unwinding
This section documents precise colorimetric data and ink-related deviations. Accurate Delta E measurements and spectrophotometer readings are critical for objective color quality assessment and determining conformance to customer specifications. Provide all available quantitative data to support deviation classification.
Spectrophotometer Model & Serial Number
Measurement Mode Used
M0 (No Filter)
M1 (D50 Daylight)
M2 (UV Excluded)
M3 (Polarized)
Measured Delta E (ΔE) Value
Color Target Reference Number
Color Channel Deviation Analysis
Color Channel | Target L*a*b* Value | Measured L*a*b* Value | Deviation (Δ) | Severity (1-5) | |
|---|---|---|---|---|---|
Cyan (C) | 55 | 56.2 | 1.2 | ||
Magenta (M) | 45 | 46.1 | 1.1 | ||
Visual Color Match Assessment Under Standard Lighting
Unacceptable Match
Poor Match
Fair Match
Good Match
Excellent Match
Is metamerism observed under different light sources?
Ink Series or Brand Used
Ink Batch or Lot Numbers
Ink Viscosity (seconds, Zahn Cup)
Ink Temperature (°C)
Primary Color Deviation Classification
Hue Shift
Chroma/Saturation Issue
Lightness Variation
Gray Balance Failure
Spot Color Mismatch
Total Color Failure
Gradation/Transition Issue
Affected Print Units or Stations
Unit 1
Unit 2
Unit 3
Unit 4
Unit 5
Unit 6
Unit 7
Unit 8
Coating Unit
Lamination Unit
Are color bar control patches within tolerance?
Customer Pre-Approved Delta E Tolerance
Overall Color Deviation Severity (1 = Minor, 5 = Critical)
Color Consistency Assessment Across Web Width
Severe Deviation | Significant Deviation | Moderate Deviation | Slight Deviation | No Deviation | |
|---|---|---|---|---|---|
Left Edge (0-20%) | |||||
Left Center (20-40%) | |||||
Center (40-60%) | |||||
Right Center (60-80%) | |||||
Right Edge (80-100%) |
Associated Image Quality Defects Observed
Dot Gain Excessive
Dot Loss/Highlight Break
Mottling
Banding
Streaking
Misregistration
Ghosting
Fill-in
Pinholing
None
This section documents substrate material characteristics, coating integrity, and structural quality parameters. Material defects often contribute to color deviations and printability issues. Comprehensive substrate evaluation is essential for root cause analysis and supplier quality management.
Primary Substrate Material Type
Coated Paperboard (SBS)
Uncoated Paperboard (CUK)
Corrugated Board
Flexible Film (PE)
Flexible Film (PP)
Flexible Film (PET)
Foil Laminate
Metallized Film
Other
Material Grade or Specification
Substrate Supplier Name
Substrate Batch or Lot Number
Roll Number
Web Width (mm)
Material Caliper/Thickness (microns)
Coating Type Applied
Aqueous Coating
UV Coating
Varnish (OPV)
Lamination Film
Metallic Coating
Soft-Touch Coating
Pearlescent Coating
No Coating
Coating Defects Identified
Coating Skip
Orange Peel
Hazing
Poor Adhesion
Crawling
Pinholes
Blistering
Mottle
None
Substrate Material Defects Observed
Gloss Variation
Color Shade Variation
Streaks/Graininess
Spots/Contamination
Calendering Marks
Edge Damage
Core Defect
Winding Defects
Dimensional Variation
None
Structural Integrity Issues
Tearing
Delamination
Brittleness
Stretching/Elongation
Curling
Warping
Poor Stiffness
Cracking on Fold
None
Is substrate dimensionally stable across web width?
Surface Energy Test Result (dynes/cm)
Are there tensile strength or elongation issues?
Substrate Moisture Content (%)
Static electricity issues affecting print quality?
Corona Treatment Level (dynes/cm)
Web tension variations detected?
Registration Accuracy Across Substrate (1 = Poor, 5 = Perfect)
Defect Location Tracking Grid
Defect Type | Machine Direction (MD) Location | Cross Direction (CD) Location | Frequency (defects/meter) | Repeat Pattern (mm) | |
|---|---|---|---|---|---|
Physical samples retained for further analysis?
This section captures press mechanical state, calibration adjustments performed, and scrap quantification. Detailed documentation of press interventions helps correlate adjustments to quality outcomes and supports continuous improvement initiatives. Accurate scrap estimation is critical for cost accountability and material reconciliation.
Press Make, Model, and Configuration
Press Running Speed at Detection (meters/minute)
Last Full Press Calibration Date
Calibration Status
Within Calibration Period
Calibration Overdue
Post-Maintenance Calibration Required
Unknown
Press Adjustments Attempted to Correct Deviation
Ink Viscosity Adjustment
Ink Temperature Modification
Anilox Roll Change
Plate Pressure Adjustment
Register Adjustment
Web Tension Adjustment
Drying Temperature Change
Press Speed Reduction
No Adjustments Made
Other
Adjustment Effectiveness (1 = No Improvement, 5 = Complete Resolution)
Scrap Inventory Classification and Estimation
Scrap Category | Quantity (units or meters) | Estimated Cost | Segregated for Analysis? | Disposition Location | |
|---|---|---|---|---|---|
Startup Waste | 150 | $45.00 | Yes | Bin-A-Startup | |
Color Deviation Scrap | 850 | $255.00 | Yes | Bin-B-Color | |
Substrate Defect Scrap | 320 | $96.00 | Yes | Bin-C-Substrate | |
Total Estimated Scrap Percentage of Job Run
Total Estimated Cost Impact of Scrap
Production Time Lost Due to Deviation (hours:minutes)
Is partial rerun of job required?
Ink Waste Volume (liters)
Substrate Waste Area (square meters)
Defect Repeat Length (mm) - if pattern repeats
Operator Notes on Press Behavior and Observations
Is immediate maintenance intervention required?
This final section ensures formal quality review and management authorization. All deviations must be evaluated by Quality Control leadership and approved by Press Room Management before final disposition. Digital evidence and signatures provide audit trail compliance and support accountability frameworks.
Quality Control Lead Name
QC Assessment Completion Timestamp
Initial Quality Verdict
Accept As-Is
Accept with Concession
Reject - Rerun Required
Reject - Scrap All
Hold for Engineering Review
Hold for Customer Approval
Final Disposition Decision
Release to Shipping
Release to Finishing
Segregate for Rework
Quarantine for Analysis
Scrap - Disposal Authorized
Return to Supplier
Is formal customer notification required per contract?
Corrective Actions Required
Press Recalibration
Ink Reformulation
Substrate Replacement
Process Parameter Change
Operator Retraining
Supplier Quality Alert
Customer Specification Review
Preventive Maintenance
None
Hold Tag or Quarantine Number
Press Room Manager Name
Manager Review and Approval Timestamp
Manager Approval Status
Approved
Approved with Conditions
Rejected - Insufficient Information
Escalate to Plant Management
Pending Further Review
Attach Digital Evidence Package (spectrophotometer readings, press logs, photos)
Upload High-Resolution Defect Photos (multiple angles, with scale reference)
Video documentation available?
Additional Comments and Recommendations
Quality Control Lead Digital Signature
Press Room Manager Digital Signature