8 most important rules to control quality in manufacturing
Time is of the essence
Manufacturing downtime is a nightmare for manufacturers. It may lead to significant delivery delays to your customers and damage the heart of your business.
You need to be able to react rapidly, run root cause analysis, identify and fix the problem, and resume full manufacturing as soon as possible.
It is essential that the data collected from the testing stations is as up to date as possible. Ideally real-time or at least within seconds of events taking place.
“Pass” or “Fail” doesn’t make the grade
Many manufacturers base their quality criteria on one key indicator – “Pass” or “Fail”. If the test result shows a “Pass”, then the unit is ready to move on to the next manufacturing stage. If the test result shows “Fail”, then the unit is sent to a technician for further analysis.
When evaluating unit quality, a simple “Pass” or “Fail” is far from sufficient. It gives you little or no information about edge cases, where one or more of the technical parameters of the unit under test are only just within its allowed tolerance. Edge cases may lead to unit failure during operation, for example in extreme environments (cold, heat, humidity, electrical overload, impact etc.).
For accurate and useful quality in manufacturing data analysis, you need to routinely review and analyse the entire test data for the unit and compare it in a meaningful way with other tested units, other testing stations and with historic test data.
Visibility of the whole process
The manufacturing process is a chain of separate but dependent assembly and testing processes, which together build our final product.
A technical problem created in one stage of manufacturing may only be found in later stage of testing. For example, a defective button assembled on a unit may only be found during functional testing several stages later.
You should expect tests results from any of your manufacturing stages to potentially influence other stages in the process. Reviewing and analyzing the data collected in one testing station in isolation is just not sufficient.
In order to see the entire picture you need to collect and analyze the end to end results according to the severity and the frequency of each problem found.
The manufacturing of your products may be taking on another continent. It may be taking place in the next room. Either way you need to be alerted so that even if you aren’t there to keep a close eye on every stage in the manufacturing line, you will still be aware of major problems the instant they happen. An automated alert mechanism, that generates notifications about critical problems on the manufacturing line, is an absolute must.
“A clever person troubleshoots the problems that a wise person avoids in the first place”. Let’s be wise and fix quality issues before they happen. A good way to achieve this is to set up a predictive mechanism that analyzes trends within the testing results and alert us to potential quality issues.
- Yes you can definitely outsource the manufacturing of your products.
- While your chosen Contract Manufacturer may come with glowing references and tick all the boxes. This does not change the fact that you must establish an independent quality in manufacturing monitoring system to ensure smooth delivery of quality products to your customers.
- The monitoring system should collect the testing data from each testing station and present an integrated end to end view of the process.
- The data collected by your quality in manufacturing monitoring system should be up to date and presented in such a way that you can carry out quick root cause analysis of issues found during the manufacturing process.
- The quality in manufacturing monitoring system should alert you when the process is out of control and provide early warning of potential failures.
Quality in manufacturing starts here
QualityLine lets you regain control over the quality of your manufacturing line even if it is located on the other side of the world.
The system helps significantly improve quality, increase yield and minimize downtime incidents.
How does it work?
Testing data is automatically and continuously collected from your testing stations located on your manufacturing line, analyze and securely upload it to analytics dashboards exclusively set for you.
You get 24/7 accurate information about each unit tested. You can overview and drill down up to a single unit, conduct quick root cause analysis and improve production quality.