03 Alerts, alarms and the quality-to-lot link

1. Control today#

Holds, release, acceptance, rejection and sign-off of a part, bin, basket or lot, and conformance, stay with the plant's quality lead (master document section 7). Stamped names the condition, alerts a named person and keeps the record; quality decides. Templates are checked in CI: only check, inspect, look at and call are allowed as verbs.

2. Alert lifecycle#

Alerts sit outside the action and signal budgets and follow alarm-management rules in the style of ISA-18.2.

flowchart TB
    %% house-style: alert-lifecycle
    subgraph life["Alert states"]
        direction LR
        act["Active"] --> ack["Acknowledged"]
        act --> esc["Escalated"]
        esc --> ack
        ack --> clr["Cleared"]
        act --> clr
        act --> shel["Shelved"]
        shel --> act
    end
    enter(["Condition true for its delay"]) --> act
    seen{{"Person taps Seen"}} --> ack
    late{{"No acknowledgement in time"}} --> esc
    false(["Condition false"]) --> clr
    admin{{"Admin shelves with reason"}} --> shel
    clr --> done(["End"])

    classDef govc fill:#fff4d6,stroke:#c99a2e,color:#000
    classDef agentc fill:#e8f0ff,stroke:#5b7bd5,color:#000
    classDef loopc fill:#eef7ee,stroke:#4f9a4f,color:#000
    class seen,late,admin govc
    class enter agentc
    class done loopc

3. Genealogy#

flowchart TB
    %% house-style: quality-genealogy
    subgraph chain["Billet to customer return"]
        direction LR
        billet["billet push"] --> part["forged part"]
        part --> bin["time bin or lot"]
        bin --> basket["HT basket or charge"]
        basket --> test["strength test"]
        bin --> reject["register rejection"]
        basket --> reject
        reject --> customer["customer return"]
    end
    back(["↩ Every link stores method and confidence"])

    classDef govc fill:#fff4d6,stroke:#c99a2e,color:#000
    classDef agentc fill:#e8f0ff,stroke:#5b7bd5,color:#000
    classDef loopc fill:#eef7ee,stroke:#4f9a4f,color:#000
    class back loopc

4. Register intake and matching#

Fields: part, date and shift, defect type, quantity (required); forging hour or bin time, stage found, charge number (wanted). Routes: daily digital export through the edge agent's file or REST connectors; a short WhatsApp form; or a reviewed photo transcription using the connectors-doc review flow.

Matching: exact (forging hour inside one bin), shift-level (spread across bins by part count), or unmatched (kept and counted). The match rate is a health metric; a low rate prompts the quality head to add the missing field. For each defect, compare reject rates of flagged and unflagged parts of the same part and shift; a monthly Pareto shows the process condition behind each top defect.

5. Calibration loop#

Physics flags start the pilot (for forging: cold-edge billets, slow transfer, first parts after a stop or part change, press force outliers; messages only on runs of parts). Once the register is matched, thresholds are set per part and defect, flags that don't go with rejects are dropped, and a combined anomaly score goes live only when its parts are shown to reject more. New thresholds are parameter rows promoted with Stamped review (06).

6. The per-basket heat-treatment record#

Built automatically per basket and kept in L2. It covers part of CQI-9 4th edition Process Table C (continuous recording, time in furnace, quench temperature, test per batch); pyrometry status (SAT, TUS), set point and band, load size per batch, quench-tank level and agitation, and quench delay per load measured from door open to load fully immersed must come from the plant. The quench-to-ageing delay is good practice or a customer requirement, not a Table C clause (public CQI-9 4th edition form):

Sent as a daily digest and returned on demand within minutes on a customer complaint. It supports the plant's audit; it does not certify conformance.

7. Alert catalog (forging sector pack templates)#

Limits come from the plant's written values in the site packVersioned, owner-reviewed plant configuration including topology; the plant sets them, not Stamped.