Quality in the Process is not by default, it comes with continuous efforts & discipline.
Discipline is to find deviations and avoid malfunctioning of machine health.
Health is to Monitor Continuously to keep performing.
Improved Performance helps to Compete better, improve Profits & to be a Sustainable organization.
Quality is an important metric of the overall assessment of business health. With better quality control measures, organizations can better manage costs, minimize waste, and prevent themselves from brand damage and obstacle that often accompanies faulty products.
Basically, quality control is the evaluation aspect of a vigorous quality management system. It focuses on what is happening at the machine or assembly level and captures, record, and classify defects. Quality control systems may contain the utilization of automated inspection systems and other SPC tools.
And quality assurance is a process assigned to preventing defects before they occur. It also contains various tools such as histograms, control charts, and IX charts to reveal trends for analysis; this allows quality managers to perform process changes for improvement.
Availability x Performance X Quality =OEE
Quality has a major impact on operational performance. An OEE of 100% means that only good parts are produced from the machines– 100% quality;
Technology can make your shop more efficient and better at quality control because the main attribute of quality control is data collecting and analysis.
We definitely recommend checking out MAPPP ZEN, which is an IIoT platform that enables manufacturers to capture real-time and quality data, and analyze the results to optimize operations and interpret the root cause of events on the production floor."
Importance of Quality in Manufacturing
Quality control is a process that utilizes best practices, strict cohesion to standards, and specifications to carry products without defects. Quality assurance is an essential part of a successful production facility. High product quality saves time and money while improving customer satisfaction. Quality is guaranteed with spot checks, statistical process control (SPC), and 100% tests to guarantee this and especially detect errors as early as possible.
Gathering data on part quality can help audit production processes and assure that standardized work and work instructions are compatible with developing quality components while minimizing waste.
Quality Improvement Techniques
There are various methods available for manufacturing quality Improvement:
Just in Time (JIT)
Just-in-Time is a significant way to reduce inventory costs and space while increasing responsiveness and flexibility. Since parts are only ordered when required, this minimizes long-term costs on raw materials and enables manufacturers to make changes to their products without being held back by dead stocks. QC must be an essential part of the equation to assure all parts arrive right before use with no disruption in production. This means Improved Quality of Products, minimized operating costs, and faster times to market.
Utilize Daily Team Maintenance
Maintenance is not only for maintenance staff. Shop floor operators can be trained to perform maintenance tasks — machine startup, performance checks, cleaning, etc. — to help assure safe, continuous equipment operation.
Companies must train operators to manage basic maintenance tasks and support them with systems and standardized procedures that help and guide daily frontline maintenance activities. This can ultimately improve production performances (including quality) while expanding the lives of production assets.
Utilizing machine condition monitoring, maintenance teams can assure that they are directed by precise equipment data to plan out maintenance activities. This will enable preventive as well as predictive maintenance.
Utilize Emerging Technology
With the emergence of the IIoT, manufacturers have cost-effective solutions that go further in connecting and carrying granular visibility to the supply chain. By collecting the data that the manufacturing processes generate, users can learn new ways to stay competitive. Analyzing OEE can help guide process improvement teams, which will eventually improve production quality.
Statistical Process Control
Statistical Process Control contains analyzing a facility’s output in statistical terms at every step in the production process. Part measurements are taken in the SPC module, and these samples are analyzed to evaluate performance (Cp, Cpk, Pp, Ppk). It’s a process utilized by many process manufacturers. The goal is to rectify, enabling managers to correct the root issue before it can destroy the entire batch in which it manifested.
The product must be compatible enough that sampling and statistical analysis will assure that no defects get through.
Tracking the number of defective products that are made on each line and during each shift will help you to rectify the origins of every individual production concern and take steps to correct it as soon as possible.
Total Quality Management (TQM)
Total quality management is a continuous process of detecting and eliminating errors. The main aim is to enhance the quality of an organization's outputs, including products and services, by continually improving internal practices. Total Quality Management also helps to ensure long-term customer loyalty and customer satisfaction.
MAPP Zen supports quality assurance through its different modules like PFMEA & DFMEA, PPAP APQP, MSA, and SPC.
Gain real-time, insights into the cause of the poor quality and create a closed-loop system of quality management.
Contact us today to learn how our machine data platform can leverage your machine data and improve your manufacturing quality.
Armstrong is India’s biggest Intralogistics automation company, with 20 years of experience, over 1000 projects, in 14 countries.
We build intelligent intralogistics solutions.
With innovative know-how, we automate your inbound, outbound, storage and sorting operations.
Our uniquely crafted solutions double your productivity, with 100% visibility and eliminate pilferage.
To enhance your profitability, we deploy Robotics, Artificial Intelligence, Machine Learning and Business Intelligence.
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The advent of internet has fundamentally changed the course of action of almost every industry.
Even though internet has been around for a while, it wasn’t until the emergence of Industry 4.0 that the digital transformation started helping the industries to evolve.
Pharma 4.0 emphasizes on building a single virtual network that connects human, data and machines.
Looking at the past trends of manufacturing, it seems that the technological transformation is much needed for pharma manufacturing as they have been facing challenges such as:
Shift from “one drug that fits all” to personalized therapies
Complex supply chains due to outsourcing activities which results in high cost of drugs
