In-Production Inspection
HYDRA In-Production Inspection
Quality under Control
The In-Production Inspection (FEP) module as the central element within HYDRA-CAQ provides great benefits and saving potential in connection with other HYDRA applications.
The data acquisition and information features of the In-Production Inspection and Statistical Process Control (SPC) can be used together with other HYDRA applications such as BDE, MDE using the same terminals and user dialogs. Consequently, separate inspection stations are not required, transit times are avoided and manufacturing processes can be considered in their entirety. Inspections can be aligned with the production processes and triggered according to specific events by integrating the machine status (e.g. production vs. downtime) and / or the produced quantities.
The Outgoing Goods Inspection, Initial Sample Inspection and Production Control Plan also have been integrated in HYDRA-FEP as the subjects are related to each other.
Inspection Planning
Inspection plans relating to articles or article groups need to be created to be able to perform in-production inspections as well as inspections for outgoing goods. To simplify matters for article groups, it is possible to create group inspection plans or family inspection plans. Specific inspection characteristics are assigned to each operation. In addition, different inspection stations can be assigned (e.g. directly at the production line or within the QA laboratory). Consequently, characteristics can be divided according to different inspection stations allowing tests at separate locations. Subject to the requirements and situation, different events triggering inspections might be relevant.
HYDRA supports inspection intervals based on the production time, intervals based on the quantities produced and tie-in with the machine status. For example, an inspection can be
triggered every three hours, every 500 units or immediatelyafter machine downtimes. A separate inspection point is generated for each event triggering an inspection.
Relevant documents (texts, pictures, videos, etc.) can be transferred to the terminal along with each inspection plan to support operators in the inspection process.
Inspection Data Collection
The corresponding inspection step including all details about the inspection characteristics to be processed are displayed immediately, once an operator logs an operation into the
production data acquisition terminal. Consequently, the machineoperators do not have to take any further steps. During the production, employees are constantly informed about pending inspections at the production data acquisitionterminal, as inspection points are generated automaticallyevery time events triggering inspections occur. Events that
triggerinspections can be, for example, if a time / unit intervalis reached or a machine status changes. Taking the inspectionplan specifications into account, inspection points include the respectively assigned characteristics depending on the triggering event.
Relationships between acquired data are established automatically as the system supports the connection between production and quality inspections. This in turn provides benefits
if the production control requires orders to be tracked in relation to quality-related events. In addition, quality data can be evaluated easily by selections based on orders, operations
or machines.
The graphic user interface of the production data acquisition terminal directly shows the inspections that are due (highlighted in yellow within the list of machines and orders) in addition to production-related data. By clicking the button “Perform inspection“ the quality inspection dialog appears and the user is navigated through the inspection process by means of an inspection list. Depending upon the characteristic type (variable, attributive or failure collection chart), there are different data acquisition dialogs that can be designed individually based on the current requirements. Corresponding messages are displayed if wrong data is input or limit values are violated. If plausibility limits are violated, data cannot be saved and a corresponding message is shown. Planned inspections can not be skipped, provided that mandatory inspections have been defined. The inspection process can be automated and made safer if data is collected via directly connected measuring equipment, such as calipers, micrometers, or similar.
The screenshot shows a sample dialog for acquiring variable characteristics.
Failure collection charts are useful for attributive inspections. Inspection data that has already been acquired and corresponding results can be viewed directly in the inspection list (left in the screenshot). Further detailed information can be displayed by clicking the button “Show info“. In addition to control charts and histograms, documents relevant to
inspections can also be displayed. Statistical parameters and the history of recorded failures can be viewed in separate functional areas.
HYDRA enables real-time monitoring of measured values and inspection data using special presentation functions directly at the machines and workstations. Consequently, specific action can be taken at an early stage. Detected quality deviations can be documented at any time by assigning failures and measures. Since Escalation Management has been integrated, users are actively notified if such events occur. Predefined workflows can be enabled if it is required to process quality deviations in more detail.
Evaluation of Inspection Results
The measured values and inspection data need to be prepared and visualized to be able to establish a control system for improving process quality. For this purpose, HYDRA-FEP provides control chart reports and failure mode analyses with efficient filter functions. Depending on the requirements, the relevant data areas (e.g. evaluations for a specific operation, article, machine, period) can be filtered and different ways of presentation can be configured and
combined.
All common control chart types are available for the evaluation of control charts.
Different configurations within the control charts are possible in order for the analysis of measurement and inspection data to provide specific results. The analyses naturally include archived data as well. Automatically generated failures document violations of limit values. The same applies to recognized trends. The generated failures allow for calculations of the current quality status during the inspection process without requiring any additional steps. Example: At the beginning of a day shift, the foreman can retrieve and check the quality deviations that occurred during the night shift.
Analyses can be designed individually by combining different control charts, diagrams and tables.
The control charts include the monitoring functions Trend, Run and Middle Third that improve process control even further. The failure mode analysis provided by HYDRA is another typical report for the QA department and other production-related areas. Here, evaluation is based on the failure type, failure location and failure cause and failure distribution (frequency) is displayed, e.g. by article (group), machine or periods in relation to the previously filtered data. Based on such analyses, it is possible to determine the core areas that require quality-improvement measures.
Evaluation scenarios are saved as profiles to be able to reuse them at a later point in time. Example: Daily checking of the
top 10 failures that have occurred per article/machine/order since the previous day at 4:00 p.m. until the current day at 8:00 a.m.
The integrated pivot and filter functions enable the data to be prepared and visualized in different ways via “drag and drop”.
Connection to Additional QA Applications
In the event that the analyses provided by HYDRA-CAQ are not sufficient, inspection data can also be transferred via an interface to the known statistic program qs-STAT. Configurable filter rules specify which data is to be transferred.
Creation of Inspection Certificates
Inspection certificates also play an important role in in-production inspection. They are considered a proof of quality and are delivered to customers along with the finished
products. Documents such as inspection reports or customer specific special certificates are requested more often and are available in many different forms and can no longer be created and managed in a reasonable and economical manner
without system support. As the customers mostly require individual layouts and contents, the forms need to be able to be designed and adapted individually. HYDRA uses
standard MS-Office functions, which helps users to create individual forms easily without requiring too much time and effort as it would be necessary for creating the forms using
report generators or similar tools.
Outgoing Goods
Some elements of the inspection functions pertaining to in-pro-duction inspection are also relevant for outgoing goods. Inspection plans, e.g. stability checks, that are especially created for outgoing goods are used in this context for inventory.
Initial Sample Inspection
As part of the initial sample inspection, product and quality characteristics of an article are defined and coordinated between the customer and supplier, e.g. prior to production
delivery. This minimizes quality risks and quality costs for both sides. However, the conventional generation and processing of initial sample inspection reports is relatively time and cost-intensive, in particular if a large variety of products and short-term product changes are involved. In contrast to this, HYDRA Initial Sample Inspection including the collection of all relevant details and their transparent documentation provides for significant streamlining.
HYDRA provides standard forms for initial sample inspections e.g. for sampling based on VDA and, as a result, supports the relevant inspection processes.
Integration of Measuring Machines
Measuring machines for complex measurements of a variety of characteristics are used especially for initial sample inspections. These machines can be integrated directly in the
automatic process of data acquisition.
Production Control Plan
Inspection plans, methods, characteristics and required gages can be combined in a general production control plan to be able to comply with the standards QS 9000 and TS 16949. HYDRA makes sure that only authorized employees are allowed to make changes to these plans, that they are versioned accordingly and that releases are managed.