Production systems and machines are now required to be faster and more flexible while adapting to continuously changing requirements for manufactured products. Industry 4.0, characterized by integrating digital technologies, automation, and data-driven decision-making in manufacturing, has given rise to Quality 4.0. It focuses on applying Industry 4.0 principles to quality management and assurance and encompasses digitizing assets, seamless communication between machines, and applying the Internet of Things (IoT) mindset to the manufacturing sector.

Quality 4.0 provides a robust system for documenting and verifying quality practices and activity, offering complete visibility into the manufacturing process from the beginning through final inspection, emphasizing traceability and tracking. This data is critical for quality control, liability protection, and ensuring the safety of products. Another benefit of Quality 4.0 is proactive risk management. By identifying and mitigating potential risks early in the production process, manufacturers can ensure quality, minimize failures, and reduce scrap losses.

The key to this transformation lies in harnessing the vast amounts of data generated by interconnected machines and measuring instruments that show trends and relationships in a manufacturing space that were previously unknown.

Enabling Quality 4.0 with Precision Gaging Tools

Precision gaging tools, such as calipers, micrometers, and digital indicators, are used to measure the dimensions and features of manufactured parts with high accuracy. Precision gaging technologies play a pivotal role in enabling Quality 4.0 by enabling accurate measurement and control of manufacturing processes.

Precision tools now include integrated wireless gages equipped with digital interfaces and data output capabilities to enable data transmission from other gages for seamless integration with digital quality control systems. With integrated wireless gages, small transmitters are built into precision gaging equipment that allows them to transmit data directly to the quality software on the computer. Each integrated transmitter uses slightly different signal coding, allowing many gaging stations to simultaneously communicate to a single computer.

Many of these tools also provide feedback by generating a signal to the operator that the computer received and acknowledged the transmission. This is virtually instantaneous so as not to slow the operator down, and most transmitters can be configured to provide a go or no-go signal to the user, depending on whether the part is within tolerance.

This transformation of analog measurements into digital data minimizes the risk of measurement mistakes and ensures consistency in data collection. It ensures that products meet specific quality standards and tolerances, essential in industries where even minor variations can lead to product defects, safety issues, or compliance problems. Furthermore, investing in integrated wireless gages has an even higher ROI in enabling a transition to Quality 4.0 as they can be used to adapt existing gages rather than investing in all new gaging.

The Importance of Data Integrity in Quality 4.0

Quality 4.0 places a strong emphasis on leveraging data for decision-making. It involves collecting and analyzing vast amounts of data from various sources, including gages, machines, sensors, and quality control systems. This data is used to identify trends, deviations, and opportunities for improvement while reducing scrap loss.

Therefore, data integrity is the backbone of Quality 4.0. Software solutions automate data collection and quality analysis tasks, providing real-time visibility into production processes while making the overall quality control process easier and more efficient.

Wireless data transmission from precision gaging tools automates data collection and eliminates manual errors while enabling the software to perform real-time analysis and visualization of measurement data. The feedback and intuitive visualizations allow operators to assess measurement quality (good or bad), take corrective actions for out-of-spec parts if needed, and record actions taken.

Beyond real-time visualizations, data is used for long-term analysis, identifying trends and opportunities for process improvement by analyzing information such as whether the process is improving or deteriorating. Are specific tools, fixtures, or operators impacting quality? What changes are occurring in process variations?

Finally, the data can be stored for long-term archiving and used for future reference, tracking, and compliance. This is required in industries such as medical devices and aerospace, where manufacturers may need to return some years later to obtain information about a particular part.

Quality 4.0 Imperatives

Three key factors ultimately ensure confidence in the overall system:

1. Data quality: Are measurements accurate and reliable? Are measurements taken and visualizations updated in real-time?
2. Operator efficiency: Are parts measured promptly and correctly?
3. Traceability: Tracking measurement origin, part numbers, and serial numbers.

Data Quality

Data collection and quality software must be universal in its ability to collect data in real-time from a wide range of gages, automated inspection, and test systems. It is equally important that all quality data collected is stored in a common database, enabling standardized analysis and reporting. Quality software must not only provide real-time feedback but also enable automated reporting and visualization to those away from the actual process to aid in management decisions for corrective actions.

Operator Efficiency

Software analysis fed by wireless data collection addresses common pain points, such as ensuring operators measure parts in a timely manner. Real-time monitoring enables supervisors to track measurement frequency and quality, identifying potential bottlenecks.

Enhanced Traceability and Compliance

Quality 4.0 emphasizes traceability throughout the production process, and it is becoming increasingly important to know when and where the data came from. Manufacturers must track the history and origin of each product or component, which is vital for quality assurance and compliance.

For example, standards are being implemented in the automotive industry with requirements regarding documented information vital to the success of the quality management system itself. In addition, there are requirements concerning verifying processes being carried out as intended, the fitness for monitoring and measurement equipment, and the documentation of monitoring and measurement activities and their results.

This can be easily implemented with software using wirelessly collected data that can be stamped with the serial number of the gage, the part number it is measuring, and a date and timestamp. This enables documentation of the measuring device used.

Case Studies: Real-World Savings

At times, manufacturers are burdened with detailed reporting requirements dictated by their customers. A stamping manufacturer reduced labor for measurement and reporting by 75% through direct electronic data collection from instruments and seamless integration to customer-dictated reporting software.

Another manufacturer saved millions of dollars per line by tracking data, using integrated wireless gages and visualization software to identify scrap causes and optimize processes. Manufacturers can achieve similar results by leveraging data integrity and Quality 4.0 principles.

Conclusion

Quality 4.0 harnesses the power of data-driven decision-making, automation, and digital technologies to revolutionize quality management and assurance. Precision gaging tools with wireless data transmission capabilities play a vital role in this transformation, ensuring accurate measurement, control, and traceability throughout the production process.

Leveraging the power of data visualization allows manufacturers to automate and simplify the process for operators while pinpointing areas for improvement and ensuring compliance. By embracing Quality 4.0 principles, manufacturers can:

• Enhance data integrity and reliability
• Improve operator efficiency and timeliness
• Ensure compliance with regulatory requirements
• Identify and mitigate risks early in production with real-time feedback to all
• Drive process improvements

Manufacturers that invest in precision gaging tools and advanced Quality 4.0 software solutions will be better positioned to thrive in the era of smart manufacturing, realizing benefits such as improved product quality, increased productivity, and reduced costs.