Improving Quality with
Without Real Quality Measurements, Scrap is Just Money Going Down The Drain.
A quality product is core to what manufacturers do. Producing a product with quality issues will result in additional costs, rework and possibly unhappy customers. Most customers rate their suppliers on a number of different quality metrics and will only award contracts to those who consistently deliver a product that meets their specifications.
Correctly calculating quality is essential to a reliable, realistic OEE. Quality measures the amount of good parts produced vs. the total parts produced. To calculate quality of a part, SensrTrx collects part counts and reject reason codes directly from the PLCs or other sensors as well as from input from operators or supervisors.
This includes data taken from specialized testing equipment and data beyond reason codes such as temperature, pressure, speeds, vision systems, and any other data points accessible from the equipment.
Pareto Charts for Measuring Quality
SensrTrx offers Pareto Charts out of the box to help determine the most common causes of scrap. SensrTrx Pareto charts come from Vilfredo Pareto who identified the 80/20 rule and created the chart that bears his name.
In this Pareto chart the number of rejected parts is grouped by reason code. In the detailed view, 80% of our scrap is caused by 2 reasons:
- Tool Break
Scrap Details by Reason
SensrTrx can be configured to measure scrap by reason in a variety of ways such as:
- Number of times a scrap reason occurred
- Average number of scrapped parts per entry
- Total number of scrapped parts by reason code.
You can also see the trend of each reason code – are we producing more scrap or less over time.
Scrap by Shift
You can look at scrap by shift and reason code to determine if one shift has more scrap than another. In this case, 3rd shift has more rejected parts that 2nd or 1st. There could be a training opportunity to improve quality.
SensrTrx allows you to track trends in your data allowing you to see over time how your plant is running. Using trends, you can easily see the effect of process or system changes over the long term. You can also notice when scrap is increasing or decreasing and quickly take action to resolve the issues.
Users can easily set up alerts when scrap is higher than normal. These alerts can notify any employee that can benefit from this information, maintenance, supervisors, or the operator of a line.
Looking for More Resources?
White Paper: Manufacturing Analytics
Find out why Manufacturing Analytics is so important to improving your machine’s performance and OEE.
Webinar: Cut Costs & Improve Efficiency
A 30-min Webinar on how to use Manufacturing Analytics to cut costs, increase availabiity and capacity.
Blog: How to Calculate and Determine OEE
Overall Equipment Efficiency is the groundbreaking formula that forms the basis of manufacturing KPIs today. Learn how in this blog.
Video: 4-minute Demo on Downtime Reduction
See in this brief, 4-minute video how SensrTrx helps manufacturing companies reduce machine downtime.
Ready to Start?
Reach out to us today and we’ll set up a customized demo of SensrTrx to help you reduce scrap and meet your needs and goals.