Quality Control Tracker

A comprehensive web-based application for tracking and managing quality control processes in manufacturing and production environments.

📋 Overview

Quality Control Tracker is a PHP-based web application designed to help organizations record, monitor, and analyze quality control inspections. The system provides a centralized platform for tracking product quality, identifying trends, and generating reports to support continuous improvement initiatives.

✨ Features

🔍 Quality Control Management

• Inspection Records: Create, view, edit, and manage detailed QC inspection records
• Pass/Fail Tracking: Record inspection results with comprehensive notes
• Batch Management: Track quality metrics by batch numbers
• Advanced Filtering: Find records by product, date range, status, and more

📊 Reporting & Analytics

• Visual Dashboard: Get an at-a-glance view of key quality metrics
• Pass Rate Analysis: Track pass/fail rates over time with visual charts
• Product Performance: Compare quality metrics across different products
• Data Export: Export records and reports to CSV format for further analysis

👥 User Management

• Role-Based Access: Three permission levels (Admin, Manager, Inspector)
• User Administration: Add, edit, and manage user accounts
• Secure Authentication: Password-protected access with encrypted storage

🏭 Product Management

• Product Catalog: Maintain a database of products subject to quality control
• Categorization: Organize products by category for easier management
• Status Control: Activate/deactivate products without losing historical data

⚙️ Administrative Tools

• System Settings: Configure application parameters
• Activity Logging: Track user actions for accountability
• Data Backup: Export system data for backup purposes

🛠️ Technologies Used

Backend

• PHP 7.4+: Server-side scripting language
• MySQL 5.7+: Relational database management system
• PDO/MySQLi: Database abstraction and prepared statements
• PHP Sessions: User authentication and state management

Frontend

• HTML5: Semantic markup structure
• CSS3: Custom styling with responsive design principles
• JavaScript: Client-side interactivity and validation
• Pure Vanilla Implementation: No frameworks for lightweight performance

Security Features

• Password Hashing: Secure credential storage using PHP's password_hash()
• Prepared Statements: Protection against SQL injection attacks
• Input Validation: Comprehensive server-side validation
• CSRF Protection: Form security measures

📦 Installation

Prerequisites

• Web server (Apache, Nginx, etc.)
• PHP 7.4 or higher
• MySQL 5.7 or higher
• mod_rewrite enabled (for clean URLs)

Step-by-Step Installation

1. Git Clone

   - git clone name_of_the_repo(link)
   - cd name_of_the_repo

2. Create a MySQL database

CREATE DATABASE qc_tracker;

3. Import the database schema

mysql -u username -p qc_tracker < database.sql

4. Configure database connection

5. Edit the config.php file with your database credentials:

$db_host = 'localhost';
$db_user = 'your_username';
$db_pass = 'your_password';
$db_name = 'qc_tracker';

5. Set up the admin user

6. Access the setup script via browser: http://yoursite.com/setup_admin.php

7. This will create an admin user with credentials:

8. Username: admin

9. Password: admin

10. Important: Delete the setup_admin.php file after creating the admin user

11. Set proper permissions

chmod 755 -R /path/to/qc-tracker
chmod 777 -R /path/to/qc-tracker/uploads (if applicable)

7. Access the application

8. Navigate to http://yoursite.com/qc-tracker/ in your web browser

9. Log in with the admin credentials

📘 Usage Guide

Adding Products

1. Log in as an admin or manager
2. Navigate to Product Management
3. Click "Add New Product"
4. Fill in the product details and save

Recording Quality Control Inspections

1. Navigate to "Add QC Record"
2. Select the product and batch number
3. Enter inspection details and set pass/fail status
4. Add any relevant notes
5. Save the record

Generating Reports

1. Navigate to the Reports section
2. Set date range and other filters as needed
3. View the generated reports
4. Export to CSV if needed

Managing Users

1. Log in as an admin
2. Navigate to User Management
3. Add, edit, or deactivate users as needed
4. Assign appropriate roles based on responsibilities

🔧 Troubleshooting

Common Issues and Solutions

Login Problems

• Issue: Unable to login with correct credentials
• Solution: Run the setup_admin.php script to reset admin credentials
• Prevention: Ensure password_hash() and password_verify() functions are compatible with your PHP version

Database Connection Errors

• Issue: "Could not connect to database" error
• Solution: Verify database credentials in config.php and ensure MySQL service is running
• Prevention: Test database connection before deployment

Blank Page or 500 Error

• Issue: Page displays blank or server returns 500 error
• Solution: Check PHP error logs and enable error reporting temporarily:

ini_set('display_errors', 1);
ini_set('display_startup_errors', 1);
error_reporting(E_ALL);

• Prevention: Implement proper error handling and logging

PHP Configuration Requirements

• session.auto_start = 0
• memory_limit = 128M (minimum)
• max_execution_time = 30 (minimum)
• file_uploads = On (if using file uploads)

🎨 Customization

Styling Modifications

The application uses a custom CSS file (styles.css) that can be easily modified to match your organization's branding:

1. Colors: Edit the CSS variables at the top of styles.css:

:root {
    --primary-color: #2563eb;
    --primary-hover: #1d4ed8;
    /* other color variables */
}

2. Logo: Replace the logo image in the header section of layout files
3. Typography: Modify font-family properties in the CSS

Adding Custom Fields

To add custom fields to quality control records:

1. Modify the database schema in database.sql
2. Update the form in add_record.php and edit_record.php
3. Adjust the display in view_record.php
4. Update the getAllRecords() function in functions.php

🔒 Security Considerations

Production Environment Recommendations

• HTTPS: Always use SSL/TLS encryption in production
• Environment Variables: Store sensitive data in environment variables instead of config files
• Regular Updates: Keep PHP and MySQL updated to patch security vulnerabilities
• File Permissions: Set restrictive file permissions (644 for files, 755 for directories)

Password Policies

Implement stronger password requirements by modifying the user creation and editing functions:

• Minimum length (8+ characters)
• Complexity requirements (uppercase, lowercase, numbers, special characters)
• Regular password rotation

🚀 Future Development

Planned Features

• Mobile Application: Native mobile apps for on-the-floor inspections
• API Integration: RESTful API for integration with other systems
• Barcode/QR Scanning: Scan product codes directly into the system
• Advanced Analytics: Statistical process control and trend analysis
• Document Management: Attach technical specifications and procedures to products

📁 Project Structure

qc-tracker/
├── index.php                 # Main entry point and dashboard
├── login.php                 # User authentication
├── config.php                # Database and application configuration
├── functions.php             # Shared functions and utilities
├── add_record.php            # Create new QC records
├── records.php               # List and filter QC records
├── view_record.php           # Detailed view of a single record
├── edit_record.php           # Modify existing records
├── reports.php               # Generate and display reports
├── admin.php                 # Admin dashboard
├── user_management.php       # User administration
├── add_user.php              # Create new users
├── edit_user.php             # Modify user accounts
├── product_management.php    # Product administration
├── add_product.php           # Create new products
├── edit_product.php          # Modify product details
├── export.php                # Data export functionality
├── setup_admin.php           # Initial admin setup (delete after use)
├── styles.css                # Application styling
└── database.sql              # Database schema and initial data

❓ FAQ

General Questions

**Q: Is this application suitable for regulated industries (e.g., pharmaceuticals, medical devices)?**A: The basic version provides fundamental QC tracking, but regulated industries may need additional validation and documentation features to meet compliance requirements.

**Q: Can multiple inspectors use the system simultaneously?**A: Yes, the application supports concurrent users with different permission levels.

**Q: Is there a limit to how many records can be stored?**A: The limit depends on your MySQL database configuration and server storage capacity.

Technical Questions

**Q: Can I integrate this with our ERP system?**A: The current version doesn't have built-in API integration, but you could develop custom connectors using the database structure.

**Q: Does the application work on mobile devices?**A: The interface is responsive and works on tablets and smartphones, though a dedicated mobile app would provide a better experience for field use.

**Q: Can we host this in the cloud?**A: Yes, the application can be hosted on any server with PHP and MySQL support, including cloud providers.

📞 Support and Contact

For support inquiries, feature requests, or bug reports, please:

• Open an issue on the GitHub repository
• Contact the development team at [senior.dev.info@proton.me]

📜 License

This project is licensed under the MIT License - see the LICENSE file for details.

🙏 Acknowledgments

• PHP - The backbone of our application
• MySQL - Reliable database management
• All contributors who have helped improve this project

Create a MySQL database

CREATE DATABASE qc_tracker;

Import the database schema

mysql -u username -p qc_tracker < database.sql

Configure database connection

• Edit the config.php file with your database credentials:

$db_host = 'localhost';
$db_user = 'your_username';
$db_pass = 'your_password';
$db_name = 'qc_tracker';

Set up the admin user

• Access the setup script via browser: http://yoursite.com/setup_admin.php

• This will create an admin user with credentials:

• Username: admin

• Password: admin

• Important: Delete the setup_admin.php file after creating the admin user

Set proper permissions

chmod 755 -R /path/to/qc-tracker
chmod 777 -R /path/to/qc-tracker/uploads (if applicable)

Access the application

• Navigate to http://yoursite.com/qc-tracker/ in your web browser
• Log in with the admin credentials