quality control

As a central element of HYDRA-CAQ, the IPQC (FEP) module is linked to other HYDRA applications and offers great benefits and savings potential. The data acquisition and information functions of IPQC and Statistical Process Control (SPC) can be used with other HYDRA applications, such as BDE/MDE using the same terminal and user dialog. Therefore, there is no need for a separate inspection position, there is no transition period, and the manufacturing process can be considered a complete process. By integrating the status of the equipment (e.g. production vs. downtime) and/or throughput, inspections can be synchronized with the production process and implemented on a case-by-event basis. Finished product inspection, initial sample inspection and control charts are integrated in HYDRA-FEP as interrelated events

Inspection plan

It is necessary to establish an inspection plan for the product or product group to complete the IPQC and outgoing inspection. To simplify product groups, you can create a group inspection plan or a family inspection plan. Assign the specified inspection characteristics to each operation. In addition, different inspection locations can be assigned (e.g. directly on the production line or in the QA laboratory). As a result, features can be distinguished based on those different inspection locations that can be tested at separate locations. Depending on the requirements and conditions, the different events that trigger the test may be interrelated. HYDRA supports inspection intervals based on production time, throughput and machine status. Such as every three hours of inspection, every 500 pieces or after shutdown inspection. A separate checkpoint is generated for each inspection event that is triggered. Relevant documents (text, pictures, videos, etc.) can be transferred to the terminal with each inspection plan to support the inspection operator.

Inspection data collection

 As soon as the operator enters an operation into the production data collection terminal, the relevant inspection steps with the details of the inspection characteristics to be processed are immediately displayed. As a result, no further action is required on the part of the machine operator. in production

During this period, the operator is constantly informed of the inspection to be carried out at the production data collection terminal, as an inspection point is automatically generated for each inspection event. For example, an inspection event is triggered when a time interval/unit time interval arrives or when the equipment status changes. Taking into account the specification of the inspection plan, the inspection points contain the specified characteristics based on the triggering event. Since the system supports the connection of production and quality inspection, the relationship between the obtained data is automatically established. This, in turn, provides benefits for the production control of quality-related work order tracking. In addition, quality data can be easily evaluated based on the selection of work orders, processes, or equipment.

The graphical user interface of the production data acquisition terminal directly displays the current inspection situation in addition to production-related data (the equipment and work order lists are highlighted in yellow). Press the "Perform Inspection" button, the quality inspection dialog box pops up, and the user operates through the inspection process on the checklist. Depending on the type of feature (variables, attributes, error synthesis plots), the different data acquisition dialogs can be individually designed according to the current requirements. If incorrect data is entered or a limit value is exceeded, the corresponding message is displayed. If the limit value is exceeded, the data cannot be saved and the corresponding information is displayed. If you have specified an enforcement inspection, you cannot skip it. If the data is collected by directly connected measuring instruments, such as calipers, micrometers and other similar instruments, the inspection process is automated and more secure.

By using the special display function directly on the machine or workstation, HYDRA monitors the measured values and inspection data in real time. Therefore, special operations can be employed at an early stage. By specifying errors and measures, detected quality deviations can be recorded at any time. Since the alert management has been integrated, the user is constantly notified in the event of such an event. If you need to deal with quality deviations more specifically, you can enable predefined workflows.

Evaluation of test results

To set up a control system to improve process quality, it is necessary to prepare and visualize the measured values and inspection data. For this purpose, HYDRA-FEP offers control chart reports and error mode analysis with efficient filtering. Based on this requirement, the relevant data areas (e.g. evaluation of specified processes, products, equipment, and cycles) can be filtered, configured and combined into different display methods.

Different combinations within the control chart may be arranged sequentially and used for measurement and test data analysis to provide specific conclusions. Data analysis naturally includes archived data as well. Automatically generated errors document limit deviations and recognized trends. During the inspection process, which does not require any additional steps, the errors that arise are related to the calculation of the current quality state. For example, at the beginning of the day shift, the foreman can retrieve and check for quality deviations that occur during the night shift.

Analyze separately with different control charts and tables.

Control charts include monitoring function trends, operations, and intermediate transition zones to further improve process control. The error pattern analysis provided by HYDRA is another typical report for QA management and other production-related areas. Here the evaluation based on the error type, the location of the error and the cause of the error as well as the distribution (frequency) of the error, e.g. by product (group), device or the period associated with the previously filtered data, are displayed. Based on this analysis, it is possible to identify the core areas where quality improvement measures need to be implemented.

The assessment is kept in an archival file so that it can be reused in a timely manner.

For example, from 4 noon the previous day to 8 a.m. the next day, perform a daily check of the top 10 errors that have occurred on each product/device/work order.

With a "drag-and-drop" mouse, the filtering function allows the data to be organized and visualized in different ways.