Create Defect Log doctype for automated defect tracking from Quality Inspections

[dwarakavikraman]

Purpose

Build institutional memory for quality defects. Every QI failure should automatically create a Defect Log entry that can be queried later — by supplier, by item, by defect type, over time.

Currently, QI inspections record pass/fail with major/minor counts, but:

• No structured record of what the specific defects were
• No root cause tracking
• No corrective action log
• No way to detect repeat patterns (same supplier + same item + same defect)
• VETRI (production AI) cannot reference history when flagging issues

Proposed Doctype: Defect Log

Fields

Field	Type	Notes
quality_inspection	Link → Essdee Quality Inspection	Auto-linked
posting_date	Date	From QI
lot	Data	From QI
item	Data	From QI
supplier_name	Data	From QI
result	Select: Fail / Hold	From QI
major_defect_count	Int	From QI
minor_defect_count	Int	From QI
defect_details	Small Text	Specific defects found (e.g. "rawedge visible, fusing sticker slanting")
root_cause	Small Text	Filled manually after investigation
corrective_action	Small Text	What was done to fix it
action_date	Date	When corrective action was taken
is_recurring	Check	Auto-set if same supplier + item + defect_details found in previous 90 days
previous_occurrence	Link → Defect Log	Link to previous occurrence if recurring
status	Select: Open / Investigating / Resolved / Recurring	Workflow

Auto-creation

• On QI submit, if result = "Fail" or "Hold", auto-create a Defect Log entry
• Pre-fill all fields from QI
• Check for previous defect logs with same supplier + item in last 90 days → auto-flag as recurring

Views needed

• List view filtered by: supplier, item, date range, status
• Report: Defect frequency by supplier (count of defects per supplier per month)
• Report: Recurring defects (same supplier + item combination)
• Report: Open defects without root cause (status = Open for > 3 days)

Business Impact

• Feb-March 2026: A.S.K Sport failed QI on Rocky Collar T-Shirt 3 times in 5 days. Without a defect log, each failure was treated as isolated. With this, the 2nd failure would auto-flag as recurring.
• 37.7% rework on Fashion Skirt Sweat — no structured way to track what defect is driving rework
• Production AI (VETRI) will query this for daily reports, supplier scorecards, and recommendations

Related

• Add configurable validation range for Piece Weight (required_pcs_weight) on Cutting LaySheet #347 (piece weight validation)
• Add approval escalation workflow when Cutting LaySheet piece weight deviates beyond ±3g #348 (piece weight approval escalation)