Testing process for manufacturing quality – Do we make it in the correct way?
Controlling manufacturing quality is always a challenge because hundreds of tasks must be successfully completed so that only quality products are shipped to our customers.
We set testing processes to help us monitor manufacturing quality.
We test each stage of the production flow, starting with the inspection of incoming raw material, right through to the final stage prior to the delivery of finished goods to your clients.
BUT, although we invest this enormous amount of effort, we still do not really control the process in real time. We still find ourselves being surprised with unexpected quality issues which cause delays in delivery, insufficient yield and unhappy customers.
What is the main reason for this situation?
Usually testing stations located on our manufacturing line (manual as well as automatic) measure many technical parameters.
The testing processes concludes with an indication – “Pass” or “Fail”. If the test result shows a “Pass”, then the unit is moved on to the next manufacturing stage. If the test result shows “Fail”, then the unit is sent to a technician for further analysis.
Why do we usually pay attention only to the “Pass” or “Fail” criteria? Why aren’t we interested in the detailed list of each of the tested parameters?
There are two main reasons for that:
- Technical difficulties to integrate and collect the testing data from different Automated Test Equipment located in our manufacturing line.
- Information overload. When running a mass manufacturing line, it is impossible to routinely “digest” all the detailed information collected from testing stations. We usually analyze this data in detail only when a critical quality problem is found and we are busy finding the root cause of the problem.
If we get a ‘Pass’, then all this detailed information is typically forgotten.
A simple “Pass” or “Fail” gives us little or no information about edge cases – where one or more of the unit’s technical parameters is 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.).
But because it is difficult for us to daily “digest” this huge amount of testing data we eventually give up on this invaluable detailed testing data and set for a minimal indication of Pass/Fail which hardly helps us to really control the process and improve quality as well as yield.
For accurate and useful quality data analysis and for best results in manufacturing quality, we need to find a method that will collect and analyze the entire test data in REAL TIME and present it as an actionable information.
Data is power and getting the data in real time already analyzed provides us with the ability to really control the manufacturing quality process.
Quality in Manufacturing starts here
QualityLine lets you regain control over the quality in manufacturing of your outsourced manufacturing line if it is located in your own facilities or 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.