For discrete manufacturers the processes related to production are littered with challenges relating to quality from version control and revisions, bills of materials, issue management, data capture, traceability, audit and reporting. Additionally, in a high mix / low volume production environment quality can be effected due to the velocity of change as operators have to deal with different product configurations as manufacturers offer more and more variance to their products.
The Hidden Factory, where quality goes to hide!
As ProcessIQ we have a term called ‘The Hidden Factory’. This term came from visiting numerous shop floors of prospects and on a number of occasions we noticed an area of the factory that was more like a dumping ground, sometimes behind a curtain. So, we asked, “what function does that area of the factory serve?” and it was typically where quality issues were being dealt with, using an offline, paper-based approach, whether you call this quarantine or re-work it seemed like a hidden part of the factory where quality, compliance, customers, company reputation & costs are impacted.
Understanding the role of quality management software and ‘The Golden Thread of Quality’.
Whilst not being thought of as pure play quality management software, comprehensive electronic work instructions software (Not quite manufacturing execution software grade) compliment many of the quality needs of manufacturers. Unlike paper and low functionality document-based software, robust electronic work instructions solutions deliver a ‘Quality built-in’ approach, whilst following a ‘Golden Thread of Quality’ throughout the production processes.
Must-have features in quality management software.
Whilst specific QMS systems are available, numerous quality functions of a comprehensive electronic work instructions solutions perform a number of key quality benefits for manufacturers that may be overlooked when reviewing potential solutions to support quality initiatives, a few of which are outlined below.
Feature 1: Document control and management
Does your shop floor operator have the latest revision of the work instruction?
Document control is critical for manufacturers to be able to see what build version was used to complete the production of a product or a product quantity for a given production or work order.
Electronic work instruction solutions provide a number of functions to support not only the electronic audit, but also the controls for a given process document to be used in production.
At ProcessIQ we provide several features to support quality in the management of versions and revisions.
Security and access control are basic requirements of any system to ensure only suitably qualified team members have the ability to for example, release the use of a build book / work instruction in production.
Customer specific workflows are defined to route the sign off process to the departmental stakeholders which automatically creates an electronic record for any future audit purposes.
Common quality challenges for shop
ProcessIQ ensures only the latest revision of electronic work instructions are available on the shop floor, removing errors between production planning and the shop floor. operators.
Shop floor Production process
Coming soon –
Feature 2: Quality data & enforcement
Feature 3: Non-conformance management
Feature 4: Audit management
Feature 5: Reporting and analytics
Conclusion
