5 processes you can automate in the quality control department to stop firefighting

Which quality control (QC) department processes can be automated with AI: the top 5 examples for boosting efficiency and cutting costs

  • AI against anxiety, or how to cancel firefighting mode
  • In minutes, AI performs a call analysis that would take employees several weeks
  • AI will check whether there is any game of telephone in communication with customers, contractors, and colleagues
  • AI is a remedy for forgetfulness: it will remind you how, when, and in what way

Main text

  1. Missed something - it is your fault; let defective product through - it is your fault again.

  2. Production errors tend to get pinned on the quality control department.

  3. Having learned from experience, quality control employees try to monitor more strictly: if it was not done perfectly, revise it; if it was not formatted properly, redo it.

  4. So here is what happens: every side wants the best, but it ends in nitpicking and shifting the blame.

  5. Every day QC specialists have to fill out and process many documents and keep hundreds of standards in mind.

  6. Often this entire system runs on manual control.

  7. That is why you have to double-check, jot things down on a slip of paper, then transfer them into the system and reconcile.

  8. This work is large and invisible, which is why neighboring departments may feel that QA is mired in bureaucracy and deliberately slows down their processes. In this article, we explain how AI makes the quality control department's work more productive, increases process transparency, and helps achieve the desired results faster.

AI against anxiety, or how to cancel firefighting mode

Quality control covers dozens of processes and hundreds of documents. That means a huge amount of routine work. The most stressful part is that the tasks never end. They all seem important and urgent, and it is unclear what to tackle first. Anxiety and fear of missing something important set in. In that state, a person gets stuck on minor details, checks the same things repeatedly, compares data endlessly, and sometimes mentally switches off and does the work on autopilot.

Tension rises, and so does pressure from colleagues, because it seems to them that requests are being ignored on purpose. _This is roughly how quality control employees look in the eyes of colleagues_ Stress leads to work errors, burnout, and a strained atmosphere in the team. To avoid this, management sees two options: - First: hire new employees to reduce the load on the existing teamBut there is a new risk here: you cannot keep expanding headcount indefinitely.

Payroll budgets are not unlimited, company resources are not either, and qualified talent is becoming increasingly scarce on the job market. On top of that, practically nothing will change: people will still process data manually, routine work and repetitive loops will remain, and burnout will still be a problem. - Second - automate the processesto reduce the number of manual operations. Technology makes this possible.

For example, AI reduces information processing time from 3 hours to 15 minutes by handling routine tasks dozens of times faster. In other words, with AI in place, the team stays the same, but constant firefighting goes away. Processes will no longer stall because of the human factor. The number of errors will decrease. The team will be able to focus on preventing problems and increase productivity.

The company will get out of the operational crisis. Tasks AI can help with today: - listen to sales managers' calls and check them for script compliance; - process negative customer reviews and draw conclusions about product quality or the supplier's reliability; - verify that documents are filled out correctly; - find errors in large data sets; - advise employees on internal policies. The only challenge in making this transition is finding a vendor with relevant experience.

It is important that the company not only has AI implementation experience, but also understands how to integrate it into business processes. Then the transition will be smooth, and employees will quickly start using the new tools. Spoiler: KT.Team has exactly this kind of experience.

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In minutes, AI performs a call analysis that would take employees several weeks

Imagine: a company sells crushed stone.

Managers follow scripts, but the conversion of calls into leads remains low.

There are two ways to solve this ↓ First: to give the employee

Marina is tasked with re-listening to the calls and writing a report on each one.

Marina will take 20 calls for evaluation, each lasting 10-15 minutes.

The task will take a whole day

_Marina listened to 20 calls, did not understand half of them, and the worst part is that these were not even representative calls.

Because the day before, the manager had chewed out the subordinates, and that day they worked better than usual.

The analytics picture came out blurred_ Second: connect AI.

There is no longer any need to test how much Marina's ears and willpower can take. You can upload all call recordings to AI → let it process them → get transcripts and analytics. In the summary, the manager will see which calls matched the scripts, which did not, and what the issue was.

Solving the task will take two hours, plus another hour

Marina spends time reading the report, having coffee and forwarding the letter to her manager.

The longest part of this process is deciding what to do with underperforming employees.

But that no longer has anything to do with either Marina or the AI tool. _Example of recommendations from an AI assistant after analyzing a customer call_

AI will check whether there is any game of telephone in communication with customers, contractors, and colleagues

Kirill - two print shop managers.

For Oleg, everything runs smoothly: projects fly along, production does not screw up, clients are happy. For Kirill, on the contrary, there are constant surprises and slip-ups.

Both try hard, their experience is roughly equal, and it is not entirely clear where the catch is.

The answer turned out to be incredibly simple: both employees read the regulations, but only

A client asked how much it costs to produce and deliver promotional brochures from city A to city B.

According to the regulations, the manager must confirm the number of brochures, the client's city of residence, the preferred delivery method, and the deadlines.

Technical details are also needed: paper type, die-cutting and varnish coating.

Once the information is collected, an order is created.

Then down the chain: production → warehouse → logistics.

Kirill, the problem is that he is used to working the old-fashioned way: he writes information in a notebook, keeps some things in his head and passes the order to production verbally.

The print shop workers, naturally, immediately forget it all or interpret it their own way.

But the main problem is not even Kirill's, but his manager's.

Because his KPIs and reputation take the hit.

If you cannot explain clearly, you are a bad manager. _What is obvious to one person may be completely unclear to another.

Following procedures helps avoid the broken telephone effect_

One of the quality control team's tasks is to help the business avoid communication breakdowns and ensure employees follow standards.

This requires monitoring many work conversations and calls.

This is exactly where an AI assistant comes in handy

AI can: - analyze calls: transcribe voice recordings and messages and extract the key points; - understand the substance of the conversation: whether the employee followed the script in a productive dialogue or improvised and failed to collect all the required data; - detect negative sentiment in communication: whether tension is building into a team conflict.

The manager receives a report on every call: a transcript and a summary.

This makes it clear what the employee is talking about, how they communicate, and how accurately. You can see whether the person follows procedures, how strong their soft skills are, and whether their product knowledge needs improvement. _Example of a call analysis by an AI assistant_

AI is a remedy for forgetfulness: it will remind you how, when, and in what way

Pyotr Ivanovich, where is the data for 2024? Semyon, I’m going on vacation tomorrow, who will cover for me?"

Most companies have regulations for every business process, from signing a contract with a supplier to going on leave. Of course, no one is urging you to memorize them — and why would you.

So the regulations sit quietly in the knowledge base until someone needs them.

You have to go somewhere, remember where the right information is, read it, and pick out the key points.

It's easier to ask the quality control department: they know everything, after all.

The circle closes. The QC department aims for order, so they answer everyone.

Time is being spent, but the team is not becoming more mindful

And it never will, as long as well-meaning QC staff keep answering colleagues at the expense of their own tasks.

To handle this situation, you can bring in an AI assistant.

It will always be ready to answer: - how to apply for leave; - what to do if you get sick; - where the business letter templates are stored; - how the bonus is calculated.

The system works as simply as any search engine.

Employees will not have to wait until a colleague is free to listen to them, or spend a long time searching the knowledge base for the right procedure. And the quality control team will have less work correcting the same mistakes. _This is how the AI bot answers an employee's question about vacation_

AI helps identify problem products or unreliable suppliers

Sometimes a particular product draws a lot of complaints, and the QC department has to figure out why. Going through complaints manually takes a long time: you have to check whether they are genuinely valid or whether customers simply disliked the color, style or material. You also need to sort the cases, rank them by frequency and frame the problem for the procurement department. For example, a customer complained about a missing part: a paper towel holder arrived without the screw connecting the rod and the base.

The customer rejected the item and filed a return. The control team must log the case in the database and check whether it is an isolated error or a systemic one. If it is systemic, they need to inspect the warehouse: why do employees repeatedly forget to include the parts? Speed matters when handling negative feedback, because until you understand the cause, customers will keep posting angry reviews.

Artificial intelligence helps here too. It will help: - understand which product has the most issues; - show the return rate and recurring complaints; - identify which batch had the highest number of returns; - sort products by groups and common issues. AI will analyze the data and provide initial recommendations. With this summary, procurement and quality control teams can resolve issues faster and more easily. _Example of analysis of purchase abandonment data and recommendations from an AI assistant_

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AI checks that documents are filled out correctly so it does not slow down related departments

Contracts, acts, supporting documents, proposals, reports - every day employees deal with filling out dozens of documents. Some people enjoy carefully proofreading every line, but most do it mechanically.

Another time a counterparty's contract is filled out incorrectly, and then the company pays penalties for warehouse storage beyond the limit.

One time the waybill isn't fully completed, the truck with the cargo gets held up at customs, and the costs once again fall on the company.

Bureaucratic language and following the rules do not come easily to everyone.

Mistakes appear because of the human factor.

Changing that is unlikely, but making mistakes practically impossible is easy. AI guarding document workflows: - spots anomalies in contracts - checking individual text fragments is much easier than proofing the whole document; - handles the job in minutes - related teams do not get blocked because the employee is not available to handle paperwork; - eliminates typos and flaws - AI does not get tired or overlook anything.

All you need to do is give the system the rules for filling out documents, and it will do the job quickly. _This is how AI checks a tender application against the policy_

People or machines: how much time and money a company spends on each

Let's compare the process and costs in both cases. To make the analysis fair, let's assume the control team is overloaded, the number of tasks keeps growing, and the team is burning out. The manager faces a choice: hire a couple more employees or take the risk and implement AI. So what will the costs look like, in rubles and in days? ↓

ProcessAINew Employee
SearchFinding the right solution, reading reviews, and reviewing the commercial proposal takes no more than a week.Average time to fill vacancies is as follows: for a manager, 60 to 180 days; for specialists and managers, up to 40-50 days; for workers, up to 30 days.
Getting startedImplementation will take 4 weeks, which sounds like a lot, but it is a one-time time investment. After that, the AI assistant will always be ready to work.You need to allocate 1-2 weeks for onboarding, and it will take another 2-3 months for the employee to settle into the rhythm. Training and supporting the new hire also falls on the shoulders of an already overloaded manager.
WorkloadAI can be deployed in different ways - for example, to strengthen the work of your employees or to take over processes entirely. And when AI is no longer needed, you can simply leave it disconnected.Even if the workload in quality control drops and the employee has no tasks, you will still have to pay a salary and provide a workplace. It will be difficult to dismiss them after the probation period.
Risks of rejecting the workAI will stay with you for as long as you want.An employee can leave at any moment, and the hiring process will have to start over.
PaymentPay around 600,000-800,000 rubles for implementation, and the assistant is yours. After that, you only need to pay for language model usage, which costs from 2,000 to 10,000 rubles per month.According to hh.ru, an entry-level quality specialist earns about 50,000 rubles, while an experienced one earns about 80,000 rubles or more. There are usually several people in the department. The more tasks they handle manually, the more people are needed.

By handing at least part of the routine work to an AI assistant, you can cut review time by 50% and give feedback in 2 hours instead of 24. Recommendations will be implemented faster, and the company will grow faster. Later, as the company scales and the volume of documents and data increases, you will not need to urgently look for new quality control staff. The AI assistant will handle any workload successfully and prevent human errors.

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