Make sense of your production data with QualityWorX
QualityWorX is for manufacturers who cannot use their production data in a manner that helps them on the day-to-day challenges of running the assembly line and quickly addressing quality or issues that affect productivity and cost money.
It is a suite of data management and manufacturing analytics software that lets you acquire and store production data from assembly processes and easily view, analyze it or create reports. It brings together all of the processes that went into building the part, providing immediate visibility into problem areas and enabling the correlation of downstream failures to upstream assembly operations. See how customers use QualityWorX by reviewing the User Stories.
Not to be confused with Statistical Process Control (SPC) or other systems, QualityWorX uniquely offers both traceability and birth history information and actionable diagnostic information for every part produced. Manufacturers have been able to drive yields to 100%, reduce costs related to scrap and rework, and compare quality across machines, lines and plants. Users have told us that QualityWorX enables actionable analysis in minutes or hours instead of the days or weeks and spreadsheets previously required.
The QualityWorX suite is comprised of a database application for centralized storage of production data; software-based connectors for data aquisition; and manufacturing reporting and analytics tools.
One database, all production data for every part, by serial number
QualityWorX collects manufacturing data from plant floor devices and stores it into a single database, providing a complete birth history record for every assembled part.
Data connectors push data from any source – any test system, PLC, tool controller or database – into QualityWorX’s fast, efficient Microsoft® SQL Server® database. Complete, detailed information on virtually all manufacturing data on a part-by-part basis is collected including:
- Full process signatures and all of their associated data, unique to QualityWorX
- Images (e.g., from machine vision systems)
- Pass/Fail status
- Scalar feature values and specification limits
- User-defined, part-specific process parameters
- Defect & repair data
- Manufacturing line configuration
Types of Data
QualityWorX acquires data from across the manufacturing line. Our growing line of connectors include:
- Popular PLCs
- Test systems, either from Sciemetric, other vendors or custom systems
- Leading brands of rundown tools
- Other tools such as welders
- Vision systems
- End-of-line tests such as hot test, leak test, cold test
- Data acquisition products
QualityWorX data can also be shared with other information management systems such as ERP or MES.
Easily retrieve, review and analyze production data and using the analytical and reporting tools that are part of the QualityWorX suite.
Many ways to view and use production data
Reporting The QualityWorX tools offer both quick and easy real-time reporting on what’s important to the production line and advanced manufacturing analytics to visualize and pinpoint problem areas.
Using the Web-based QualityWorX Dashboard you can create your manufacturing reports with just a few clicks.
Set up the visual dashboard using the library of charts and gauges or run reports that include:
- Part History report
- First time yield
- Summary report
- Trend browser
- Failure Pareto
- Failure report
- Defect Pareto
- Repair Traffic
Most of the Dashboard reports allow users to click through to detailed reports on the data, drilling down from a high level summary to in-depth detail with just a few clicks.
For advanced manufacturing analytics, Engineering Workstation features a powerful mathematical processing engine that can simultaneously analyze thousands of waveforms, rapidly simulate a broad range of test scenarios using historical data, or identify defects using line-wide trends and correlations. These advanced capabilities are combined with a suite of standard reports to provide the ultimate in data analysis and reporting environments. Engineering Workstation is ideally suited for Manufacturing and Quality Engineers who are tasked with developing and implementing new production processes, maximizing production yields, optimizing throughput, and identifying root causes.
Repair Bay Manager
Faster diagnosis of failures and traceability
The Repair Bay Manager (RBM) is a flexible repair management solution that can be tailored to virtually any assembly process and repair strategy. The RBM application connects to a QualityWorX database to provide repair operators with a simple, intuitive interface for diagnosing failures and recording defect and repair data for long term traceability.
Faster diagnosis and repair
RBM allows operators to diagnose failures faster with a comprehensive part history review tool that provides real-time access and display all waveforms recorded for the defective part, isolate and identify defect digital process signatures and features to rapidly highlight only those nodes that need to be repaired. Instructions on how to repair known issues can also be included.
Complete traceability on stripback and repairs
All data, including 3rd party data, defect and repair data, operator identity and comments, are aggregated into a consolidated birth history record that is tied to the part’s serial number in the QualityWorX database. Comprehensive reporting on defect and repairs can be done through the QualityWorX Dashboard.
Turnkey solution for RBM Stand
Sciemetric can provide the entire stand to meet a plant’s requirements, including enclosures, hardware, the software and installation services. Contact your Sciemetric representative for more information.
Eliminate the guesswork: use facts to optimize your line
Too many manufacturers rely on guesswork to optimize their lines. QualityWorX gives you the hard facts that help balance both yield and quality, while reducing costs. Here are some ways manufacturers have benefited from using QualityWorX.
Drive First Time Yield to 100%
Use the tools to quickly identify the root causes of defects that are keeping you up at night. Unlike SPC which only indicates there is a problem, QualityWorX lets you specifically identify and fix it, improving FTY. The use of digital process signature analysis also provides insight into the underlying physical processes that create defects.
- One leading powertrain manufacturer was able to realize a 5% increase in First Time Through (FTT) while significantly reducing the cost per assembled part.
Optimize Test Station Performance
Using QualityWorX’s analysis tools, you can quickly develop or optimize test algorithms and limits and try them out on historical data before applying to live production, eliminating the need for time-consuming sequential trials. You can also compare parallel stations to determine the reasons for differences in performance.
- QualityWorX reduced months of effort to a couple of days for optimizing leak tests for one manufacturer of manifolds. Instead of months of trial and error to find the optimal settings and limits, using QualityWorX analysis tools on stored test data quickly determined the best part of the waveform for extracting the leak rate and to optimize test limits.
Launch New Lines More Quickly
You can reduce the time required to launch production on new manufacturing lines using QualityWorX to determine the appropriate test algorithms and test limits. It enables the use of common metrics to simplify comparisons across the line and around the world to ensure consistent quality throughout the enterprise. Having the data means a more efficient run-off process.
- The launch of new production lines for one Sciemetric customer have gone from 180-360 days down to 15-45, resulting in faster time to market and reduced costs.
Control Quality Spills to the Affected Parts
In the case of a suspected quality issue, QualityWorX lets you analyze the data of affected parts and compare it against all of the suspects – whether it’s hundreds or thousands or more – of units to determine which fit the profile. This enables you to quickly and confidently conduct a pinpoint recall while also allowing you to figure out what went wrong and prevent it from reoccurring.
- An automotive manufacturer facing a potential recall of 10,000 vehicles due to a problem discovered in a customer vehicle was able to quickly diagnose the problem, identify the defect and compare it against historical data, pinpointing the seven defective parts by serial number.
Reduce Manpower and Downtime
Having the ability to use the production data enables manufacturers to run their assembly tests and processes more efficiently, with fewer people and less downtime. The ability to set up a machine quickly, to get the most out of it and keep it running is critical in a plant and results in significant cost reductions.
- One manufacturing manager had a process that required up to six people per shift and was causing one of the leading quality issues with the part downstream. Implementing Sciemetric in-process testing combined with QualityWorX virtually eliminated the manufacturing defects and resulted in a reliable process that required only a single operator per shift.