Today’s manufacturers have to provide customers with more options, which increases the number of product variants but also the complexity. The reasons for this can be found in the increasing demands of customers, but also in the greater complexity of products. In addition to this, they are required to work with smaller batch sizes, more diverse portfolios and generally a shorter time-to-market.
This challenge is referred to as “mass individualization”. The aim is to provide every customer with the product he or she wants at a price that is equivalent to that of a comparable mass-produced standard product – and of course in the best possible quality. Those who successfully serve the desired product variety can in turn secure new market segments and customer groups.
The growing complexity of production processes, the increased availability of data and rising production speeds, coupled with ever stricter regulations and reduced capacities, are creating an enormous challenge in the day-to-day work of quality managers.
Not only do they have to carry out more specific tests, but they also have to document, research, keep track of and communicate more, all at the same time:
When it comes to quality management, many different product variants mean a departure from parameter lists that could be applied countless times. In the past, conventional software solutions for support could be set up with the corresponding forms, images, characteristics and tolerance limits. This is no longer sufficient: manually adjusting the inspection plans consumes too much time and money and is too prone to errors.
New software solutions have the ability to create automatic inspection plans, inspection reports and forms so you don’t have to start afresh for each variant. This means that only one data import is necessary for generating the inspection plans and evaluations for the variant in question.
For manufacturers of electronic or mechatronic systems, the firmware factor is an additional parameter at this point.
In the absence of an integrated data exchange option, the quality manager has to gather the relevant characteristics for each variant himself and build an inspection plan. However, important information is often also contained in a variety of different systems, such as Excel, SAP and special supplier systems. Integrated quality management software is able to generate an inspection plan using data from different systems – which means that intelligent quality management does not have to involve a comprehensive reorganization of the IT landscape: a unified overview can be generated by the software in spite of the different systems.
Quality management has to deal with mass data in many cases. Out of this mega-data conglomerate, data needs to be prepared in such a way that it is easy to see where the problems lie and, in the case of an alert, to be able to quickly work through the data to see where the issue is arising and find any correlations. This kind of in-depth analysis is only possible when different parameters can be brought together by the software.
The application of a generic structure that clusters variants into product families provides a target-oriented approach that has become established in the field of semiconductor and PCB manufacturing. In this way, “lessons learned” can also be inherited by related variants.
A holistic quality management system provides the industrial manufacturing industry with the support it needs to increase customer satisfaction while complying with business rules, current standards like DIN/ISO/VDA and requirements according to the MSA (AIAG). Consistent use of a quality management solution helps to avoid cost-intensive recalls and supports you in collecting and processing even very large amounts of data. The modular design of our QDA solution means you can use it according to your needs:
By means of various modules we enable you a scalable digital quality management adapted to your needs.
Do you have specific questions about our solutions? Get in touch!
Director QDA SOLUTIONS