Challenges in practice
In modern manufacturing, speed is crucial—quality testing should support this and not be an additional burden. Changing personnel, short cycle times, and high variant diversity often lead to incomplete documentation and delayed responses to process deviations in practice. Tests are often adjusted rigidly or manually, while process and machine parameters are not recorded consistently and comprehensively. As a result, deviations in process capability are only detected once scrap, rework, or downtime have already occurred. At the same time, there is increasing pressure to provide audit-proof and traceable test reports at all times.
Solution QS1
Our solution for production testing is part of an integrated CAQ system that maps quality along the entire value chain. Production testing forms the operational core: process and quality data are generated directly in production and are available in real time for evaluations, decisions, and follow-up steps.
With integrated statistical process control (SPC), you can continuously monitor relevant inspection and process parameters and detect deviations at an early stage. Based on a dynamic approach, inspection scopes can be controlled as needed – from close-meshed inspection to reduction in stable processes. Inspections can be controlled on a process-specific basis, e.g., for first article, series, and final part inspections, and are directly linked to the respective process steps.
If quality deviations occur, other modules such as error and complaint management and action tracking are seamlessly activated. Deviations from production testing are recorded in a structured manner, evaluated, and tracked until corrective and improvement measures are effectively implemented.
Thanks to full integration into the ERP system, all relevant master data and order information—from articles and characteristics to parts lists and work plans to production orders—are available in real time. QA data thus becomes an integral part of the value chain and at the same time forms the data basis for further methods such as FMEA, continuous improvement processes, and forward-looking quality strategies.
- ERP-based inspection orders: Automatic inspection orders for production orders and work steps from the ERP.
- Mobile feedback: Simple interface for inspection on mobile devices.
- Workflow control: Workflow-based order processing and automatic information distribution.
- Integrated LIMS: Seamlessly integrated laboratory information and management system.
- Test station control: Flexible control and organization of test stations.
- Barcode integration: Faster start to testing with barcode scans.
- Individual feedback: Freely configurable feedback interfaces at feature level.
- Measuring equipment connection: Connection of common hand-held measuring equipment, testing machines, and analysis devices.
- Traceability: Batches, serial numbers, cavities, additional data, and process parameters.
- Audit trail: Complete history and audit trail at all data levels.
- Digital signatures: Dual control principle and GxP support.
- Forms & certificates: Standard forms and certificate creation.
- Complaint management: Derivation of complaints directly from errors.
- Assembly support: Batch and serial number assignment in assembly processes.
- SPC & key figures: Control charts, key figures, and capability analyses.
- Document control: Centralized, versioned document control.
- Analyses & dashboards: Key figures, analyses, and dashboards.
- FMEA feedback: Mirroring of actual errors in the FMEA database.
- Supplier management: Quality data for supplier evaluation and certificates.
- Qualification management: Qualification checks via the QS1 qualification matrix for ERP and BDE postings.
Does this sound familiar?
- Inspections “run along,” but cannot be controlled: Inspections, documentation, and approvals take place on the shop floor—varying depending on the shift/person, making comparison difficult.
- Inspection orders are created manually or too late: Production orders are approved, but the inspection orders/specifications lag behind. The result: rework, queries, delays.
- Process parameters are missing from the documentation: Measured values are documented, but machine/process parameters (temperature, pressure, etc.) are not clearly indicated in the test results. This can be problematic during audits or in the event of deviations.
- SPC is “parallel” instead of integrated: Control charts/capabilities exist, but are not an integral part of the testing process and the response to deviations.
- NIO results are not consistently followed up: Deviations are detected, but the complaint/action chain does not start cleanly or immediately.
- Test results are still recorded on paper and only transferred to the system later: Deviations are detected too late, and process indicators such as Cpk tip unnoticed because the evaluation only takes place retrospectively during entry.
This should be achieved through a robust process
- End-to-end chain along the value chain: Production-accompanying inspection => Final inspection => (if necessary) Approval including verification.
- Deep ERP integration in real time: Production order, work steps, resources, articles/material characteristics, parts lists <=> Inspection specifications and inspection orders.
- Automatic, rule-based generation of inspection orders upon release of production orders without manual “QA side world.”
- Guided, standardized data entry: attributive/variable, including additional information (texts, images, documents, CAD) and relevant process parameters for each characteristic.
- Dynamic inspection depth: sampling plans with clear stages (e.g., setup inspection => first piece => SPC series inspections => last piece) and defined response logic in case of deviations.
Coverage in QS1
- Instead of rigid checklists for each line, QS1 links inspections to the product, workstation, and ERP work process, so it is always clear which inspection applies to each manufacturing step.
- Automatically generates inspection orders from the ERP system when production orders are released and distributes them throughout the company in a targeted manner via workflow/processes.
- Guides employees intuitively through attributive and variable inspections; context-related information (texts, images, documents, CAD) is available for each characteristic in the inspection step.
- Integrates process parameters and SPC elements into the production inspection so that deviations are detected early and documented reliably.
- Automatically starts the follow-up process in the event of a non-conformance: the responsible department is informed, and the deviation is processed in a structured manner in the complaint module, including inspection report/portal approvals.
- Fast data entry via tablet/mobile devices for acceptance inspections at the factory (e.g., OEM).
Your result: Less administrative effort for test plans, more stable processes thanks to integrated SPC logic, faster response to deviations, audit-proof documentation even in series production and for complex manufacturing/assembly processes.
Your advantages
- End-to-end quality management: Production testing, SPC, error and complaint processing, and action management are seamlessly integrated—without system breaks or redundant data entry.
- Early detection & rapid response: Process and quality deviations are detected at an early stage and automatically transferred to structured error and action processes.
- ERP-integrated quality assurance: Real-time integration into your ERP system means that QA data is generated directly in the production process, seamlessly and consistently complementing the value chain.
- Reduced administrative effort: Automated inspection orders and clearly structured assignments of inspections at different levels minimize the effort required for maintenance and administration.
- Guided & secure inspection processes: Graphical inspection notes and clear inspection specifications support inspectors in the production environment – even with changing personnel or high time pressure.
- Reliable data for FMEA & CIP: Consistent inspection, process, and error data provide a sound basis for risk analyses, FMEA, root cause analyses, and sustainable improvement measures.
- Transparency down to the last detail: Cavity-related feedback for molded parts enables targeted root cause analysis and supports fast, effective troubleshooting.
