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Quality Control in Manufacturing

To compete in the global marketplace, manufacturers need global transformation.

General Manufacturing Quality Control

Manufacturing quality control solutions from InfinityQS help reduce recalls, improve product consistency and reduce costs.

Regardless of whether you have one manufacturing plant or multiple plants across the globe, you face:

  • Increasing global competition
  • A need to produce the highest quality products
  • A continual need to drive down costs
  • Supplies sourced from across globe
Quality managers in all kinds of manufacturing companies—including those making roller bearings, refrigeration compressors, building products, bicycles, athletic footwear, and flash drives—rely on InfinityQS® Statistical Process Control (SPC) software to help them:
  • Improve quality data collection
  • Proactively prevent nonconformities
  • Better monitor, analyze, and report on quality metrics

 

General Manufacturing Quality Control

InfinityQS’s industrial statisticians and application engineers have real-world manufacturing experience in a broad array of industries, including short-run or high-mix/low-volume production environments where SPC can be especially challenging. We can apply our vast knowledge of quality intelligence to improve your most pressing manufacturing quality control challenges.

General Cable saved on raw materials by decreasing inconsistencies.

Real-time visibility into the manufacturing process to control quality and reduce costs

InfinityQS automates real-time data collection and analysis on the shop floor to enable the early detection of problems, so the team can take action to prevent additional defects and nonconformities. This early prevention reduces scrap, rework, and recalls, providing significant savings to the bottom line.

Manufacturers using InfinityQS solutions improve their quality control and reduce the risk of recall by dramatically reducing process variation. And Lot Genealogy and Reporting functionality minimizes recall costs by enabling tracking of raw material lot codes throughout the manufacturing process. Based on these cost reductions and quality control measures in production, you’ll be able to demonstrate a significant return on investment within a very short timeframe.

Real-time visibility to reduce costs

In a recent survey of our customer base, customers reported they reduced their scrap by an average rate of 12.7% per week. They also reported an average 14.3% reduction in man-hours for rework.

Operational efficiency and continuous improvement

InfinityQS solutions eliminate paper-based data collection and storage systems by automating data collection through electronic gauges, PLCs, mobile devices, or operator workstations. Not only does eliminating paper-based processes make operations less costly and more accurate, but it also makes audits, compliance, and reporting a much simpler task. (No more spreadsheets!)

InfinityQS is a key part of a Six Sigma effort to improve overall manufacturing quality control, customer satisfaction, and productivity every day.

Operational efficiency and continuous improvement

With InfinityQS solutions, all quality data is stored in a single Unified Data Repository, which can also pull data from disparate systems, allowing users to:
 
  • More closely monitor and analyze processes
  • Prioritize quality improvement efforts
  • Deliver continuous process improvements

Reporting and analytics

InfinityQS provides real-time and accurate data from the shop floor to the corner office. Quality managers gain real-time visibility within plants and across plants, even on a global basis, to proactively:
  • Compare production line capability
  • Ensure product consistency
  • Reduce costs
Our customers gain the biggest improvements and cost savings by evaluating statistical data from a higher level—comparing performance across plants, processes, shifts, parts, and lots to find the next biggest opportunities for reducing costs and minimizing waste.
InfinityQS Reporting and Analytics

With InfinityQS cloud-based solutions, manufacturers can gain real-time visibility into their suppliers’ shop floor quality data before nonconforming product even ships. This enhanced level of supplier monitoring can eliminate acceptance sampling, improve quality control, and reduce inventories resulting in additional cost savings.

International Elevator Company

 

Elevating Quality to the Top Floor

Out-of-spec elevator wall panels were causing costly construction site delays. InfinityQS enabled this international elevator company to quickly identify where panel processes were flawed—and take immediate corrective action.
An international elevator company faced a costly ongoing problem. Out-of-spec wall panels were causing job site construction delays that ranged from 2 to 7 days—angering customers, costing time and money, and jeopardizing the goodwill of installation crews.
A focused InfinityQS process analysis project quickly identified the problem and enabled the manufacturer to correct the issue. From there, an expanded implementation of InfinityQS quickly enabled improved data collection and analysis across operations. Operator input during configuration ensured InfinityQS was eagerly adopted by users, who tout:
 
  • Streamlined and automated data collection
  • Improved data accuracy
  • Reduced process data analysis from weeks to minutes
  • Reduced production turnaround times by 40-60%
  • Improved certification audit frequency and rigor
  • Ability to use data to make smarter business decisions

Download the full case study to learn how this elevator manufacturer uses InfinityQS to support a broad array of high-value improvement initiatives.

 

Get the Case Study

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We were trying to gain a perspective about what the data is telling us. What does it point to about opportunities we have? We wanted to do less troubleshooting and work on improving processes rather than resolving production issues.
Donald S. Bruce
Director of Reliability Engineering at Cooper Tires
Because quality is synonymous with the Cooper brand, we looked to InfinityQS to ensure that every process met the Cooper standard. We investigated a few different options and decided that InfinityQS provided the best SPC solution to handle the complexities of our manufacturing operations.
Donald S. Bruce
Director of Reliability Engineering at Cooper Tires
By incorporating a Manufacturing Intelligence platform with an SPC engine into our plant floor quality efforts, Coty has realized benefits across all parts of the value chain – from quality professionals that experience unprecedented database accuracy, to executives seeing financial savings.
Romina Colautti
Process Engineer at Coty
The implementation of InfinityQS ProFicient is creating visibility across our global manufacturing base and elevating the level of trust in the data. This work helps us identify opportunities, improve process variations and control raw material usage, as we continue to uphold General Cable’s commitment to produce quality products for our customers.
Zack Tran
Project Manager at General Cable
The key to successfully implementing SPC is not only making sure data are collected frequently—a single data point isn’t meaningful—but also knowing what to do with the data after they are collected. By utilizing control charts in InfinityQS ProFicient, we can clearly identify trends in our processes and make adjustments accordingly. In one case, our actions resulted in significant increases in processes capability and that makes me very happy. If a process is capable, it improves product quality and save money on all fronts.
Zack Tran
Project Manager at General Cable
Our plant needed a real-time solution that would decrease the amount of time that we spent measuring on the shop floor.
Shawn Stauffer
Quality Manager at Leggett & Platt, Inc.
Though weight data was already being collected in the carbon molding area, we needed to implement a paperless system to help the operators respond in real-time to out-of-control signals. Improving Trek’s use of SPC in the OCLV molding area is another way of ensuring our ‘Best in Class’ status as a bicycle manufacturer.
Ben Fisher
Product Manufacturing Engineer at Trek
Analyzing the data real-time allows us to separate the special causes from the common cause variation and to have the operators react only when special cause variation is present.
Ben Fisher
Product Manufacturing Engineer at Trek

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