Real Time SPC and QC Shop Floor System

Challenges
SPC1
Nowadays, manufacturing companies face intense economic and competitive pressure. Many companies manage their business and operation information within an integrated ERP or SAP system. However, the actual process and quality control environment is still very often managed manually.

Typically, when a manufacturer implements a quality control procedure that involves measuring something, they start by purchasing a measuring instrument (e.g. a caliper, micrometer,height gage, bore gage, force gage, CMM, etc.) from one of the many metrology companies.

The manufacturer might then develop a procedure for measuring their parts where someone is given the task of taking measurements and writing them down on a piece of paper. The measurements would then be keyed into either a spreadsheet or a dedicated SPC software program for analysis by an engineer. Obviously this method has some potential pitfalls since people are involved in the manual data collection and data entry part of the process. Manual data entry is slow and tedious and people make mistakes.

Video of Blue Ocean Real Time SPC System

Solutions
A more accurate and more efficient approach to data collection is to enter data. The manufacturer might then develop a procedure for measuring their parts where someone is given the task of taking measurements and writing them down on a piece of paper. The measurements would then be keyed into either a spreadsheet or a dedicated SPC software program for analysis by an engineer. Obviously this method has some potential pitfalls since people are involved in the manual data collection and data entry part of the process. Manual data entry is slow and tedious and people make mistakes from your measuring instruments directly into a spreadsheet or SPC program. Most measuring tools today are available with some form of electronic output making it possible to connect the instrument to data loggers, printers or to a computer, thereby eliminating the steps of manually writing down measurements and typing them in.

Blue Ocean Real Time Shop Floor QC System

 

Automating data collection removes all possibility of human error and it also allows for real time data analysis. In addition to collecting an accurate computerized record, it is also possible to control an entire process based on the input from the tools that you use to measure the process. This type of automation creates an extremely efficient process designed to maintain the manufacturer’s quality control standards.

Benefits

  • Reduce operation cost and improvement company competitive advantage
  • Online reporting system can be used for online process troubleshooting
  • Free engineers time for more value added job instead of SPC & Cpk report preparation
  • Increase customer satisfaction
  • Allow SPC to be implemented in a “sincere” manner
  • Transparent and allow management to know what happening in shop floor
  • Allow fast and immediate actions to be taken once quality problem is detected