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 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.
Pareto Charts for Measuring Quality
SensrTrx offers Pareto charts out of the box to help determine the most common causes of scrap.
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 and tool break.
Other Solutions That Help Your Business
Track Availability & Reduce Downtime
You can determine the What, Why, Who, and When of all of your downtime. SensrTrx gives you the power to track availability and all downtime by reason code directly from the PLCs and operators.
Increase Throughput & Performance
Measure actual cycle time and compare against the standard. Identify bottlenecks and track cycle time improvements. Get alerts when performance is higher or lower than normal.
Correlate Process Data with Downtime & Scrap
Process data can affect downtime, quality, and throughput. If you correlate process data to the corresponding issues such as downtime and scrap, you will know exactly when an issue occurred.
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 see 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.
Get alerts via email or the mobile phone app.
Looking for More Resources?
Blog: How to Calculate and Determine OEE
Overall Equipment Efficiency is the formula that forms the basis of manufacturing KPIs today. Learn how in this blog.
Webinar: Start Small, Think Big, Move Fast
A 30-min webinar on how to get started with manufacturing analytics by adopting a start small, move fast approach.
Case Study: Reduce Downtime by 73%
Find out how one manufacturer was able to eliminate weekend overtime and reduce overall downtime by 73%.
Video: 4-minute Demo on Replacing Excel & Paper
See in this brief, 4-minute video how SensrTrx helps manufacturers get off of pen & paper and Excel.