Manage the Quality Control Plan in the Quality Management Software

• Define required Quality Checks across the whole factory from in-line checks to the Lab; set up Attributes and Variables to record, define frequencies and sample sizes
• Define Variable Specifications (as tolerances or absolute values – USL/LSL) including single sided tolerances; add optional plausible limits
• Grade Variables and Attributes; e.g. critical, major, minor
• Define event-based checks for certain circumstances; e.g. at job start, when a lot is created or after an out-of-spec reading
• Version control the quality plan: if a specification changes, the old and new versions are kept and the measurement data is tied to the correct specification

Manual Data Collection

• Ensure checks are systematically done by prompting operators to perform manual checks or take samples
• Line Operatives can enter the measurement data directly into screens

Automatic Data Capture

• Automatically import measurement data from other systems; e.g. CMMs, spectrometers, bespoke gauges or camera systems
• Connection to gauges via the RS232 port e.g. scales and dimensional gauges – to reduce typing and eliminate errors

Alerts

• Instant alerts to issues e.g. when measurements are out-of-spec; or out-of-control (see SPC); or if critical defects are found
• Dashboards highlight quality issues instantly for operators and quality inspectors on the shop floor to take action

Continuous Improvement

• Optionally record Causes and Actions when problems arise (requires the Concerns & CAPA module)

Quality Inspections

• Carry out AQL (Acceptance Quality Limit) inspection routines
• Follow ISO2859

Reporting

• Measurement values
• Recorded quality checks – what has been done
• Issues: out-of-spec measurements, defects found
• Process Capability Indices e.g. Cp, Cpk 
• Control Plan Conformance – did you do all the checks required in the shift?
• Insight: Pareto analysis, trends
• Customer certificates

• Improve Quality by enforcing the Control Plan - all our customers notice how quickly the system drives up the level of checks recorded and the quality of data captured. Quality improves
• Improve customer confidence – customers like to see that you have modern systems driving quality control
• Lower the cost of quality – capture and analyse data automatically; speed up reporting; do more with less
• React faster - problems can’t go unnoticed, they are immediately visible and can be escalated. Think how many times you wish you’d known sooner!
• Save time - manage by exception – no wading through good data as you will be notified when there is a problem
• Improve effectiveness - one place for all quality data, easily accessible to all, from anywhere, provided in a consistent and easy to use format
• Support continuous improvement – build up a repository of quality data and measurements; use it to identify top issues and trends; make improvements; measure and sustain
• Manage the Control Plan – one place to create and maintain the quality control plan. Check adherence to plan and identify areas for improvement

See how manufacturers are using the Quality module of Shopfloor-Online MES software and to what benefit:

Automotive

►Nissan (Sunderland) case study
Well-known vehicle manufacturer increases efficiency and enhances quality control with all quality data now monitored in a web-based factory information system.

►GKN Land Systems (formerly Chassis Systems Ltd) case study
Vehicle parts manufacturer gains real-time visibility of quality data across the factory, facilitating improved throughput and efficiency.

►Le Bélier case study
Leading parts manufacturer increases production and improves quality with Shopfloor-Online MES software.

Food & Beverages

►Ball (formerly Rexam) case study
Global beverage can maker focuses on quality control with Shopfloor-Online MES system.

►Pladis (formerly United Biscuits) case study
Biscuit manufacturer improves quality assurance and compliance with Shopfloor-Online; customer quality audits are reduced to 2 hours compared to 3 days.

Packaging

►PET Bottle Manufacturer case study
PET bottle manufacturer increases customer satisfaction with Quality Management software from Lighthouse Systems.

Medical Devices

►Plastibell case study
Injection moulding manufacturer automates quality management resulting in improved traceability and efficiency.

Shopfloor-Online provides the platform for a comprehensive quality management system to help you better implement Quality Control. Get more value from the Quality module by using it in conjunction with other modules:

• SPC – automatically generate SPC charts from all quality data and provide real-time alarm generation if measured values break control limits or trend rules
• Links to Documents – provide operators with documented procedures like SOPs or procedures describing how to do the quality check, available in one-click
• Concerns/CAPA – automatically generate Concerns (non-Conformance) under specific circumstances. Manage Concerns to closure e.g. containment action, corrective action, preventative action
• Process Parameters – beside quality measurements capture real-time process data e.g. oven temperatures, speeds, pressures, cooling, flows, volumes