Quality control software for manufacturing enables the manufacturers to perform various tasks related to quality control in their business. Aspects like how to setup a QC System, who should use QC software, what are the advantages and disadvantages of using quality management software for manufacturing, where to find free quality management system software are discussed in this guide.
In this guide, we review the aspects of Quality Control Software For Manufacturing, Which software is used in manufacturing industry, free quality management system software, and how to do quality control in production process.
Quality Control Software For Manufacturing
Real-time data has revolutionised the manufacturing industry. But it’s not enough just to have access to data. You need the right tools to make sense of it and use it properly. That’s where quality control software comes in! Here are five modules that will help you transform your operations today and in the future…
OPTIMISATION
Optimisation is a process that is used to reduce costs, increase productivity and improve quality. It also helps to reduce waste and cycle time.
Optimisation makes sure that the right amount of material or product is used at the right place in the manufacturing process. It can be done by using mathematical formulas to calculate how much material should be used for each operation or step in a manufacturing process.
For example, let’s say you are making earrings out of gold and silver wire. Optimisation will allow you to determine how much silver wire was used during each stage of production: cutting the wire into pieces, twisting them together and attaching them onto studs (which are sold separately).
COMPLIANCE
There are many different types of compliance, but generally, it means a company’s ability to meet its legal obligations. In the manufacturing world, this means ensuring that each manufactured product meets the specific quality standards required by law.
Compliance is important because it helps ensure that a company does not violate any laws or regulations in the area of quality assurance. It also helps companies meet certain contractual obligations with customers and suppliers by monitoring their performance levels and ensuring they are meeting agreed-upon criteria at all times.
VENDOR TRACKING
VENDOR TRACKING
Vendor tracking software allows you to track your vendors, suppliers and their performance. Having a good system in place that allows you to see the quality of products they are providing can help prevent large problems down the road. It’s also important to keep track of costs so that you know how much money is being spent on each product or service.
WORKFLOW MANAGEMENT
Workflow management software is used to manage the process of a business, allowing you to see what tasks are being performed and who completed those tasks. It allows you to monitor the progress of a project, assign tasks and follow up on their completion. This can be done using Gantt charts or other visual dashboards.
When it comes time to report on your project’s results, workflow management software allows you to generate detailed reports that include data from all participants’ computers on your team.
TRANSACTION MANAGEMENT
Transaction management is one of the most important aspects of quality control software for manufacturing. It involves tracking all transactions from the supplier to your company, so that you can make sure that everything is done properly. This includes managing workflow and compliance for suppliers, vendors, and customers.
REAL-TIME ANALYTICS
Real-time analytics is a process that provides data analytics to improve process efficiency. It helps to identify bottlenecks and inefficiencies, key performance indicators, trends, patterns and anomalies in the data.
Real-time analytics can also be used to improve the quality of the data. It may seem counterintuitive at first glance but by measuring what’s happening on an ongoing basis you can spot problems before they become too big or impact other systems or processes. This allows you to identify issues before they get out of hand which will save costs down the road too!
Which software is used in manufacturing industry
Manufacturing industry production software has been around for many decades. As it has evolved, it has revolutionized production processes across different industries. And it is used in process, discrete, and mixed-mode production to manage, track, and improve production.Companies that use manufacturing software can grow their businesses by enabling greater control of processes and resources to drive optimal output. These manufacturers can better control and manage costs and processes, improve product quality, ensure on-time customer shipments, and more.
What is Manufacturing Production Software?
Manufacturing production software manages the many functions and processes of end-to-end manufacturing, including material supply and inventory, labor and equipment costs, performance tracking, production planning, as well as accounting.
Traditionally, production companies managed manufacturing processes manually. This included tracking, change orders, inventory management, equipment condition, and more. These manual steps were often error-prone, inaccurate, open to biased analysis, and were usually outdated, immediately creating a lag between understanding needs and the execution of solutions.
Paper-based manufacturing is time-consuming, error prone, and not scalable.
The computer age introduced an ever-increasing and evolving software ecosystem that allowed companies to automate these processes for better accuracy and control. Early systems were usually on-premises and costly, making them attainable to only the largest of enterprises.As software development evolved, new deployment models such as software as a service (SaaS) began to level the playing field. This opened the door to modular, customizable, cloud-based, lower-cost software solutions and enabled small to medium-sized businesses (SMBs) to utilize the same level of software as larger competitors.Today, management software used in manufacturing is flexible and agile and introduces automated functionality to plan, execute, manage, monitor, and adjust production systems and production scheduling, deploy robust quality management, and accurately plan the supply chain. This includes visibility from incoming inventory from the supply chain through lifecycle management depending on the product.
The Importance of Using Production Software
Manufacturing software is essential because it provides the automated capability to control costs and optimize processes. In fast-paced production environments, process optimization is critical as it automates the tracking and analysis of production from start to finish.This means that all aspects of manufacturing can be controlled and executed under one umbrella. Production management solutions can view progress, identify bottlenecks and act to clear them with access to data and analysis at the spindle, machine, or shop floor level.Manufacturing software also offers production scheduling that helps manage the workflow within production. It can be linked to scheduling software and other platforms such as ERP or quality management software. It helps to better control costs and manage the production process. And it can ensure that production levels are on track and the right mix and balance of orders are running at the most efficient rate while still meeting customer demands and increasing customer satisfaction.
What Are the Types of Manufacturing Production Software?
There are many types of production software available, and the marketplace for solutions can be quite confusing given the variety of features available. Many can be used alone or in combination with other software.
The most important component in building a solution ecosystem is ensuring that the management systems have access to the most accurate, real-time data possible. This ensures processes can be optimized according to fact, not gut isntinct or estimates. The source of this real-time production data are the machine assets across the shop floor, and their data can be unlocked with a machine data platform.
With the machine data component in place, other production software solutions will become far more effective:
Material Requirements Planning (MRP)
MRP is one of the oldest software platforms used by manufacturing businesses. In MRP, productivity is increased on the shop floor by managing the inventory levels required for producing goods. With multi-level BOMs, MRP can explode raw materials down to the component level with the amount needed for each part. It can be further linked to purchase requirements and “on-hand” versus “available” inventory. Production schedules can be produced to optimize the right product and activity on the shop floor.
Enterprise Resource Planning (ERP)
ERP is used in manufacturing businesses at the enterprise level. Manufacturing ERP software platforms have the same functionality and purpose as MRP but also link these functionalities to human resources, accounting, purchasing, sales, and marketing. The added data layer can make the MRP functionality more dynamic and accurate as it is tied directly to incoming sales and demand data.
Manufacturing Execution Systems (MES)
MES is a type of manufacturing solution that signals an attempt to tie raw materials processing through the shop floor all the way to finished goods in real-time. Manufacturing execution system software can manage a variety of functions across the operation including quality control, production, maintenance, labor, and others. The downside of MES is that the data supporting how these functions are managed is based on inaccurate, delayed data and the overall approach is material and process-centric.
Industrial Data Platforms
The first step in any Industry 4.0 journey is unlocking the machine data from the assets actually engaging in production. With the right solution, data from varying makes and models of equipment is standardized into a common data model and instantly available in pre-built reports for consumptoon.
This data, coupled with key contextual data from operators, provides the foundation for a digital thread that can be leveraged in a cross-functional, scalable approach, that will not only provide immediate insight into production performance but fuel other management systems with the accurate data they need to manage their corresponding functions.
Top Manufacturing Production Software Benefits
For companies looking to improve their manufacturing practices, there are many benefits for tracking and managing manufacturing production with software. With the right ecosystem of solutions in palce, there are an unlimited number of use cases that can be supported. Here are some of the primary benefits:
1. Improved Inventory Management
Inventory purchasing and holding costs can place a drag on a company’s cash flow. With automated inventory tracking, manufacturing operations can realize better inventory control to ensure that they have what they need when they need it.
2. Better Labor and Equipment Utilization
With MRP, shop floor activity can be planned to meet the complexity of the product mix. This means better utilization of labor resources. With machine monitoring solutions, manufacturers can also squeeze greater capacity out of their equipment by identifying and reducing downtime and other forms of waste.
3. Improved Overall Equipment Effectiveness (OEE)
Companies can optimize processes and unlock capacity with reliable schedules that reflect accurate BOMs and routings. Downtime can be reduced with scheduled maintenance done during changeovers. You can also quickly adjust schedules impacted by a breakdown. This improves OEE and reduces CAPEX spending.
4. Optimized Purchasing
Because manufacturing software allows for cost rollups into the BOM, it can be linked to machine speed, product mix data, and other incoming information captured at the machine. From this, economic ordering strategies can be developed to enhance supply chain models with dynamic purchase order management.
5. Enhanced Production Planning
With real-time information, scheduling software can work with production and other management software to enhance the quality, accuracy, and achievability of production schedules and improve the manufacturing process.
6. Process Optimization
For manufacturing software platforms that also utilize MES or OPT strategies, processes can be improved by eliminating bottlenecks, increasing OEE, and eliminating non-value processes.
free quality management system software
What is SafetyCulture?
SafetyCulture is an award-winning digital tool that allows streamlining of inspections and audits as well as the automation of real-time reports and recordkeeping. As a quality management system software, SafetyCulture helps increase employee engagement and encourages proactive alignment with internal processes and industry best practices by continuously reinforcing compliance with standardized processes in operations.
SafetyCulture features highlight
Most useful for organizations that are subject to strict compliance with regulations and standards, the ETQ Reliance software is utilized by businesses in manufacturing, food & beverage, automotive, biochemical, pharmaceuticals, and aerospace for their QMS needs.
ETQ Reliance features highlight
Qualio is a QMS app specially made for industries in life sciences or organizations involved in pharmaceuticals, manufacture of medical devices, and in biotechnology. As a web and cloud-based software, it meets the multiple needs of quality teams while at the same time addressing other pain points such as burdensome paperwork through automation.
Qualio features highlight
Available both on web and mobile, AssurX is a versatile QMS software that allows flexibility for organizations that use its features—utilize what they currently require and implement others as needed later.
AssurX features highlight
EdApp is a microlearning software, available on web and mobile, that makes learning easy and accessible for employees wherever they may be. The EdApp software makes training more engaging for employees by integrating features such as learning metrics and gamification in its training lessons. Using the EdApp software, all QMS-related learning courses can be built and seamlessly cascaded to the intended audience, making standardized training for quality more efficient and easy to update.
EdApp features highlight
What are the Practical uses of QMS Software?
With the aim to consistently comply with quality standards, QMS software can be used for reinforcing the implementation of internal policies through regular checks and inspections by QA specialists. Operations supervisors can use QMS software to show proof that the standard operating procedures (SOP) are being followed on the production floor by submitting timely reports that reflect how staff are currently performing. Managers can monitor quality and analyze data by gaining an overview of trends in QMS software’s analytics. The entire operations, at different levels and departments, can contribute to the concerted effort to maintain quality through a QMS software that is versatile and easy to use.
Benefits of Using a Reliable Quality Management System Software
Which is the Best QMS Software for you?
A variety of QMS software offers features that can be ideal for different users depending on their business needs, type of business, or size of the organization. With these in mind, check these 5 software to help you choose which might be the best quality management software for your business.
Reasons to Pick SafetyCulture as your QMS Software
Convert, create or use pre-built digital templates
Use the SafetyCulture software to easily convert your paper checklists or spreadsheets into mobile-ready inspection forms in minutes. Build responsive, custom digital templates from scratch with our simple drag-and-drop template builder or start with a pre-built checklist from our expansive template library. Keep QMS documentation in one place for ISO 9001, GMP, HACCP, and 5S inspections.
Foster accountability
SafetyCulture enables process owners to collaborate and develop effective digital compliance checklists and implement the necessary actions for regulatory compliance. It also allows them to automate workflows so accountable personnel receive push notifications for assigned actions and inspections.
Improve visibility across the organization
By centralizing oversight through the web dashboard, SafetyCulture saves process owners time and resources by eliminating manual compliance monitoring. Track completion of tasks and inspections across multiple locations, immediately see red flags, and make decisions when they matter most.
Sample Scenario for SafetyCulture
Using the international standard ISO 9001:2015 as an example for a QMS framework, it is worth considering a risk-based strategy for your company’s QMS, particularly in the management of corrective actions. With SafetyCulture, businesses can easily benefit from thorough risk assessment using digital checklists that integrate a risk-based thinking process which help guide auditors when conducting ISO 9001-compliant audits.
Here are some tips on how you can utilize SafetyCulture in this scenario to help you create corrective actions that reduce or eliminate risk:
Quality managers and their teams can choose an appropriate risk analysis technique to determine the severity of a non-conformance and decide if a corrective action is needed. The most frequently used approaches are FMEA and HAZOP. This is a good way to integrate risk management early in the process, making it easier to identify the risk level and impact an issue brings to the organization.
Once a corrective action is deemed necessary, the quality team and process owners can collaborate and use an ISO 9001:2015 – compliant corrective action report template to document their plan’s progress
ISO 9001:2015 highly recommends establishing a cross-functional team when planning corrective actions. Quality teams can encourage this approach by using a compliance software that facilitates collaboration across teams and sites. The 5 Whys and 8 Disciplines of Problem-Solving (8D) approaches are good root-cause analysis techniques that can help team members collaborate when drafting problem statements, identifying root causes, and formulating solutions to address non-conformance.
If you are looking for cost-efficient QMS software to help you achieve ISO 9001 certification, SafetyCulture is the solution. As a web-and-mobile app solution, the SafetyCulture ISO 9001 QMS Software is easy to implement across your internal quality audit teams. Auditors can use their mobile devices to conduct comprehensive quality audits on-the-go, while quality managers can utilize the central SafetyCulture web dashboard to get a bird’s-eye view of all ISO 9001 quality audits. Download the SafetyCulture Software for free today and discover how it makes ISO 9001 certification easier to achieve.
Why is SafetyCulture Essential for an Effective QMS
Businesses involved in manufacturing, construction, hospitality, and other industries have been implementing QMS with the use of paper and pen for quality checks. While this traditional method has allowed QC and QA specialists complete quality checks, critical data can get lost in the process and collected information can be difficult to track over time. This inefficient method makes the implementation of QMS tedious, time-consuming, and prone to inaccuracies.
Below are 3 reasons why you should consider integrating a QMS software like SafetyCulture into your organization’s quality processes.
1. Gain better visibility
Get real-time data about what’s happening in your business. Using one software, you can be aware of the frequency of completed quality inspections, current performance, and quality issues. Highlight areas that need improvement and monitor results over time. Learn more about reporting & analytics.
2. Share accountability
Easily distribute responsibilities and share accountability within your organization with SafetyCulture. Empower your team to be your eyes in the field by performing inspections and audits using their mobile or tablet device. Connect your team with QM operations to collect consistent data, standardize operations, send reports, and identify and resolve failed areas swiftly. Learn more about corrective actions here
3. Maintain consistency
Ensure consistent quality in every step of the production process by performing regular quality checks using a digital checklist. By doing so, you can be confident that only high-quality products go out the door.
Using a QMS software such as SafetyCulture replaces the tedious process of pen and paper checks with digital inspections that allows your data to be instantly saved in the cloud, making it easy for you to retrieve information when needed. With a QMS software like SafetyCulture, there’s no need to manually compile data; you can automatically generate comprehensive reports every time you finish a quality check using the app. This saves you time—time you can better spend on other important areas of your business.
how to do quality control in production process
Quality control (QC) is a process through which a business seeks to ensure that product quality is maintained or improved. Quality control requires the company to create an environment where management and employees strive for perfection. This is done by training personnel, creating benchmarks for product quality, and testing products to check for statistically significant variations.
A significant aspect of quality control is the establishment of well-defined controls. These controls help standardize both production and reactions to quality issues. Limiting room for error by specifying which production activities are to be completed by which personnel reduces the chance that employees will be involved in tasks for which they do not have adequate training.
Understanding Quality Control (QC)
Quality control involves testing units and determining if they are within the specifications for the final product. The purpose of the testing is to determine any needs for corrective actions in the manufacturing process. Good quality control helps companies meet consumer demands for better products.
Why Is QC Needed?
Creating a product is costly, time-consuming, and can be unsafe without controls in place. Additionally, if a company sends defective products out for purchase, it could be held liable for injuries or issues that arise from using its products. Quality control inspectors ensure that defective or unsafe products are identified, and the causes are corrected.
How Is It Done?
Quality testing is generally completed in each step of a manufacturing or business process. Employees often begin by testing raw materials, pulling samples from the manufacturing line, and testing the finished product. Testing at the various stages of manufacturing helps identify where a production problem is occurring and the remedial steps it requires to prevent it in the future.
In a non-manufacturing business, quality testing can involve customer service evaluations, questionnaires, surveys, inspections, or audits. A business can use any process or method to verify that its end product or service meets the customer’s needs and is safe and legal.
QC Is Different by Industry
The quality control used in a business is highly dependent on the product or industry. For example, in food and drug manufacturing, quality control includes ensuring the product does not make a consumer sick, so the company performs chemical and microbiological testing of samples from the production line.
In aircraft manufacturing, quality control and assurance is of the utmost importance. Manufacturers are required to document, track, and inspect, and reinspect all items and phases of a build to build evidence that everything is completed to very strict standards.
In automobile manufacturing, quality control focuses on parts meeting specifications and tolerances. QC ensures engines, drive trains, and other mechanical parts operate smoothly, efficiently, safely, and as designed.
In electronics, quality testing might involve using meters that measure the flow of electricity and stress testing.
Quality Control vs. Quality Assurance
Quality control and quality assurance are terms often used to define the same thing, but there are distinct differences. Quality control focuses on quality requirements, such as ensuring a part meets specifications. Quality assurance refers to the sum of all actions and processes needed to demonstrate that quality requirements are fulfilled.
What this difference means for quality professionals is that as you move through a quality control career, you might transition from quality control to quality assurance. Quality control is part of quality assurance, which are programs and departments that assure upper-level management, customers, and government inspectors that products meet all quality requirements and safety standards.
Types of Quality Control Methods
There are several methods quality control uses to communicate and track inspections and issues. For instance, a quality control chart is a graphic that depicts whether sampled products or processes are meeting their intended specifications—and, if not, the degree by which they vary from those specifications.
When one chart analyzes a specific product attribute, it is called a univariate chart. A chart that measures variances in several product attributes is called a multivariate chart. Tracking variances allows businesses to see how many defects per production unit they produce and what types of defects are occurring. Here are a few examples of some methods used.
X-Bar Chart
Randomly selected products are tested for the given attributes the chart is tracking. A common form of a quality control chart is the X-Bar Chart, where the y-axis on the graph tracks the degree to which the variance of the tested attribute is acceptable. The x-axis tracks the samples tested. Analyzing the variance pattern on this chart helps you determine if defects are occurring randomly or systematically.
Taguchi Method
The Taguchi Method of quality control is another approach that emphasizes the roles of research and development, product design, and product development in reducing the occurrence of defects and failures in products. The Taguchi Method considers design more important than the manufacturing process in quality control and tries to eliminate variances in production before they can occur.
100% Inspection Method
This 100% inspection method is a quality control process involving looking at and assessing all product parts. This type of quality control is done to rule out flaws in products. This method is often used to evaluate valuable metals and produce. The 100% inspection method calls for data about the manufacturing process and software to analyze inventory.
The challenge of using this method is that looking at every single item used to build a product is expensive and could destabilize or render the product unusable. For example, if you use this method to examine organic strawberries, you risk damaging the berries, rendering them unsellable.
Quality control methods help standardize production and reactions to quality issues in various industries, from food production to automobile manufacturing.