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Manufacturing Quality Control Systems

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Manufacturing Quality Control Systems

Scrap, waste, and rework are some areas that influence the throughput of a company’s manufacturing process and, more importantly, the bottom line. If any one of these areas is lagging you can expect to see a dip in overall plant performance.

In order to mitigate such risks and help ensure consistent products, Sophos Electronic offers full quality systems. Quality systems help to monitor the production process in order to identify and predict issues in order to cut down on the amount of waste. Through combining software modules such as at-line/in-line testing, electronic work instructions, electronic work flows, corrective actions, alarms, statistical process control (SPC), and LIMS, a company can achieve the following functionality and more:

  • System enforces mandatory checks and executes routine calculations ensuring complete accountability of required test/procedures
  • Violations are automatically identified and trigger immediate corrective action processes
  • Documentation is complete, with electronic signatures captured when required
  • Auditors, supervisors, and other personnel are notified of critical limit deviations and regulatory violations
  • Approval process (e.g. HACCP, Label compliance, weights) ensures that checks have been done properly before product is released
  • Lot records are kept against process orders (prod schedules) with full genealogy of materials used for accurate and speedy recovery
  • Traceability information is rapidly available

Levering on such functionality helps to answer market challenges such as linking quality operations to actual production operations and improving regulatory compliance by fostering a company's commitment to sound controls, quality management practices and effective compliance to ensure product integrity throughout the product life cycle.

Sophos Electronic quality systems adhere to compliance standards such as 21 CFR Part 11 and provide real time feedback to the management during production, helping them react sooner to issues which arise during production.

Below is a list of benefits often realized with a electronic quality system:

  • Yield improvement by 10%
  • High reduction of production scrap
  • Reduction of rework by 50%
  • Laboratory Cost Reduction
  • Reduction in Quality Holds by 1/2
  • Right first time, TQM
  • Work Life Simplification by thousands of hours
  • Reduce Process Variation (Std Deviation) by 50%
  • SOP standardization across different production facilities

Statistical Process Control (SPC)

Process variation is the enemy of a manufacturing organization. It drives up production costs and increases risk of defective units.

Statistical Process Control (SPC) methods can be used to combat process variation by allowing you to monitor your processes and ensure that they are operating at full potential while minimizing waste.

With a Sophos Electronic SPC solution, your company can reduce cost and minimize risk.

Sophos Electronic has implemented successful SPC systems for many clients. Driven by complex mathematical formulas, our SPC solutions can provide your company essential functionality including:

  • Process trending through average, range, standard deviation, moving average and moving range charts
  • Defect analysis through P, NP, C, U and Pareto charts
  • Variable and defect acquisition
  • Automatic, semi-automatic manual, and external data acquisition
  • Real-time index monitoring
  • Control rule alarms and corrective action triggering
  • Standard OLE for Process Control (OPC) communication
  • Historical reporting
  • Contextualize data with orders, materials and lines

Sophos Electronic has the experience to help your company develop solutions to become more efficient and more profitable. Our expertise in statistically maintaining the quality of your product allows you to pass the benefits on to the end user. These key benefits include:

  • Reduce process variations
  • Reduce defects and defective units
  • Reduce human error during production
  • Reduce manual operation during production
  • Maintain higher quality standard
  • Maintain equipment performance
  • Enable real-time monitoring of quality trends

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