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Job 02 · Quality

// Metal finishing job shops · Process certifications

The cert for a finished lot, drafted from your records and held against the PO.

A lot comes off the line, and someone pulls the thickness or hardness readings, the tank log or furnace record and any salt spray result the order asked for, then types a certificate that has to match the customer's PO. In a free AI proof of concept, AI drafts those certs again on copies of 20 to 30 lots you already shipped, showing the spec called out, each reading against its range, and every record the order wants that your files don't show. Your reviewer, the member of your quality staff who knows your certs best, judges each draft against the one that actually went out.

Book a proof-of-concept call30 minutes with Rob
Finished lots
20 to 30
Certificates signed
None; quality staff do that
Lots ruled on
None

// The one job

From the records a lot leaves behind to a cert quality staff can sign

When a lot finishes, the proof that it was done right is scattered: gauge readings or hardness checks, a tank log or furnace record, perhaps a salt spray panel or a coating test, and the customer's PO saying which of those it wants to see. Quality staff assemble that into a certificate naming the spec, the results and the lot, and their signature goes on it.

In the test, AI reads copies of those records for lots you already shipped and drafts the certificate in your layout, sets every reading beside the range it was held against, notes the method used, and lists what the order required but the records don't show. It never marks a lot as passing, and nothing goes to a customer or onto a live certificate.

Lot recordsCopies only
Customer PO
Gauge readings
Tank or furnace log
Salt spray or hardness
ReadingRangeMethod
Invented records, no customer's lot
Checked against
the PO
Draft certificateFor quality staff
Spec called out
Lot and part
Results
Gaps listed
CheckReadingGap
Made-up certificate, for illustration

// Where certs come apart

A cert is only as good as the record behind it

A salt spray result needs a definition of failure. ASTM B117 tells you how to run the cabinet, and its scope leaves the interpretation of results to someone else, while warning that reproducibility depends heavily on the specimens and the evaluation criteria chosen. So a certificate reading "salt spray per B117" says how the cabinet was operated and nothing about what counted as a failure. The hours and the failure point must come from the order, the customer's spec or your own test record; the draft cites where it found each, and lists it as a gap when it can't.

Adhesion has two methods and a strict scale. ASTM D3359 rates adhesion by tape test, with Method A aimed at coating systems over 125 micrometers (5 mils) in total and Method B at thinner ones, and it tells users to establish the film thickness first if it isn't known, with a practice such as D7091. Ranks run 0 to 5 with no values in between, and the test doesn't separate higher levels of adhesion from each other. It also isn't technically equivalent to ISO 2409, so a record citing one doesn't quietly answer a PO asking for the other. The draft compares the method in your record with the film thickness and flags a 4.5 if one shows up.

A thickness number needs its method beside it. Zinc over steel is commonly read magnetically under B499, anodize on aluminum by eddy current under B244, and a cross section under B487 means cutting the part. The X-ray method in B568 measures the mass of coating per unit area and yields a thickness only when the coating's density is known. Each reading on the draft carries its method and the units it was taken in, and one with no method behind it goes on the list for quality staff.

Hardness scales don't convert cleanly. ASTM E140's tables relate Brinell, Vickers, Rockwell and other scales, but the standard calls conversion only an approximate process, to be used when the material can't be tested under the conditions specified. A print in Rockwell C and a certificate reporting Brinell gets called out, even where a table might put the number in range. A furnace chart, a quench record and a hardness check each prove something different too, so the draft won't let one stand in for another.

Public buyers spell out their certificates. Iowa DOT's Materials IM 568, for steel products powder coated for its projects, has an authorized representative of an approved shop certify the coating and that the powder came from approved sources, with a copy going to the project engineer and the District Materials Engineer at shipment. The same memo puts powder film at 3.0 to 4.0 mils unless otherwise specified and checks cure by solvent rub. Those terms govern Iowa's work only, and they show how one buyer's written rule becomes fields on a certificate. Which spec governs your lot stays with your quality staff; nothing on this page is legal or engineering advice.

// What you send

What your quality office hands over

Copies only
Certs already issued
01

20 to 30 shipped lots

For each, the customer PO, the traveler and the certificate that went out. Include a lot with salt spray, a lot with a hardness check, and one where quality held the cert for something.

02

The records behind each cert

Gauge printouts, hardness logs, tank logs, furnace charts and salt spray or adhesion records, as exports, printouts or photos of a log book.

03

Your certificate layouts

The forms you issue, by customer where they differ, along with the wording your quality staff use on each.

04

What customers ask for

Standing instructions from customers on what a cert has to state, where your agreement with them allows sharing.

05

NDA signed, nothing live

Signed before any record moves. No login to your shop system, your ERP or your lab equipment, and no live certificate opened or changed.

06

Stand-in records if needed

If a customer's terms keep test data in your building, we build look-alike lots with you that keep the same ranges, methods and gaps.

// Before it starts

Settled in writing, ahead of the first record

Your owner and quality manager agree on each line before any file is copied.

Certification test termsSet by the owner
Your reviewer
The owner's pick, usually the quality manager
Success criteria
In writing: which readings must match, which gaps must be listed
Layouts
Yours, by customer where they differ
Who decides
Quality staff: acceptance, holds and every signature
Price
A range for running it live, given up front

// How it's scored

The cert that went out, beside the draft

Certificate by certificate
scored by your quality staff
On the same shipped lotsThe cert that went outThe AI draft
Time from lot finished to a certificate ready to signFilled in from your lotsFilled in from your lots
Specification, class and type as the PO called them outFilled in from your lotsFilled in from your lots
Readings set against the range, with unitsFilled in from your lotsFilled in from your lots
Test method named beside each readingFilled in from your lotsFilled in from your lots
Salt spray, hardness or other required records attachedFilled in from your lotsFilled in from your lots
Gaps listed for quality staffFilled in from your lotsFilled in from your lots
No lot marked as passing or failingFilled in from your lotsFilled in from your lots
Blank until your lots run. Every cell waits for drafts built from your own shipped lots.The verdict on each row is your reviewer's.

// After a yes

A month on finished lots

With your reviewer's yes, certificates get drafted on newly finished lots for about 30 days.

Quality staff review, correct and sign each one before it goes anywhere. The drafts never stand in for their judgment, and scoring stays on through the month.

// Possible next jobs

What could follow certs

Ideas, not commitments
Each priced on its own
  1. 01

    Customer POs into draft travelers

    The same orders read at the front end, so a job's traveler and its cert start from one reading of the PO.

    Next
  2. 02

    Quotes for repeat work

    Piece, pound or load pricing pulled from what you charged before, for your estimator to confirm.

    Then
  3. 03

    Waste manifests and discharge records

    Hauler paperwork and lab results lined up for your environmental lead, with nothing filed or signed.

    After that

// One hard limit

It never rules that a lot passes, and it never signs.

The proof of concept doesn't touch your ERP, shop system or lab equipment or a live certificate. It sets readings beside ranges and lists gaps, and that is where it stops. Whether a lot meets its specification, and every signature on a certificate, stay with your quality staff. Defense and aerospace work stays out of the sample.

Priced per job. You get a range before the proof of concept and a fixed price before you sign.

Rob bases the range on certificates issued per month and how many different record types sit behind them.

// Questions

Certification questions

What happens when a reading falls outside the range?
The draft shows the reading, the range and where the range came from, and flags it for quality staff. It doesn't reject the lot or write a nonconformance. Your people decide what to do next, the same as today.
Our gauges and hardness testers don't export anything. Does that matter?
No. Printouts, log books and photos of a gauge readout all work for the test, as long as the numbers can be read. Nothing connects to your lab equipment at any point.
One customer wants salt spray results on every lot. Can the draft handle that?
It can list the requirement and attach the record your files hold for that lot. If the hours or the failure point aren't in the order or the record, the draft says so rather than filling them in.
Do we have to send you copies of the ASTM standards?
No. Standards you've purchased stay with you. The test works from the range, class and type your orders and records state, and anything it can't tell from those goes to quality staff as a question.
Does it look at the parts themselves?
No, it reads paperwork only. Appearance calls stay with your inspectors; ASTM F1941, for one, says slight discoloration from baking or rack contact isn't grounds for rejection, and that takes a person looking at the part.
Who signs the certificate?
Your quality staff, every time, during the test and in the live month alike. A draft has no signature and no stamp, and nothing reaches a customer unless your people send it.
Rob Eason

Rob Eason, founder

// Book a proof of concept call

Start with certs you've already signed.

Half an hour with Rob covering your processes, your role, the job to test and roughly how many certificates go out each month. Certs and test records stay in your shop until the NDA is signed.

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