Improving Quality with

Manufacturing Analytics

Without Real Quality Measurements, Scrap is Just Money Going Down The Drain.

Measuring Quality

Production 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.

OEE: Improve Quality

We talk a lot about Overall Equipment Effectiveness, the benefits of measuring OEE and using it in process improvement projects. As you know OEE is made up of 3 basic components

  • Quality
  • Availability
  • Performance

Calculate Quality

Correctly calculating quality is essential to a reliable, realistic OEE. Quality measures the amount of good parts produced vs total parts produced. To calculate Quality of a part, SensrTrx collects part counts and reject reason codes directly from the PLCs or other sensors. SensrTrx can also augment this information with 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 Manufacturing 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:

  • Scratch
  • 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 also look at scrap by shift and reason code to determine if one shift has more scrap than another. Scrap can be analyzed by shift. In this case, 3rd shift has more rejected parts that 2nd or 1st. There may be a training opportunity to improve quality.

    Scrap Trends

    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.

    Scrap Alerts

    Using SensrTrx users can easily setup 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?

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    White Paper: Manufacturing Analytics

    Find out why Manufacturing Analytics is so important to improving your machine’s performance and OEE.

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    Webinar: Cut Costs & Improve Efficiency

    A 30-min Webinar on how to use Manufacturing Analytics to cut costs, increase availabiity and capacity.

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    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.

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    Video: 4-minute Demo on Reducing Scrap

    See in this brief, 4-minute video how SensrTrx helps manufacturing companies reduce scrap.

    Ready to Start?

    Reach out to us today and we'll set up a customized demo of SensrTrx to meet your needs and goals.

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