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What are the best MES-enabled quality control practices in Industry 4.0?

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Quality control is a crucial aspect of manufacturing operations, especially in the era of Industry 4.0, where digital transformation, smart devices, and data analytics are reshaping the production landscape. To ensure consistent quality, efficiency, and compliance, manufacturers need to adopt effective quality control practices that leverage the power of manufacturing execution systems (MES). MES are software solutions that integrate, monitor, and optimize the various processes and resources involved in manufacturing, from planning and scheduling to execution and analysis. In this article, we will explore some of the best MES-enabled quality control practices that can help manufacturers achieve higher quality standards and performance in Industry 4.0.

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1 Define quality objectives and metrics

The first step to implement MES-enabled quality control is to define the quality objectives and metrics that align with the strategic goals and customer expectations of the manufacturer. Quality objectives are the specific outcomes that the manufacturer wants to achieve in terms of quality, such as reducing defects, improving customer satisfaction, or meeting regulatory requirements. Quality metrics are the measurable indicators that track the progress and performance of the quality objectives, such as defect rate, yield, scrap, rework, or customer feedback. By defining quality objectives and metrics, the manufacturer can set clear and realistic targets, communicate them to the relevant stakeholders, and monitor them through the MES.

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Brahmananda Sahoo

customer Quality Engineer at MINDA CORPORATION LIMITED, SPARK MINDA GROUP,
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The second step to implement MES-enabled quality control is to automate the data collection and analysis of the quality metrics. Data is the key to quality improvement in Industry 4.0, as it provides valuable insights into the performance, issues, and opportunities of the manufacturing processes.

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2 Automate data collection and analysis

The second step to implement MES-enabled quality control is to automate the data collection and analysis of the quality metrics. Data is the key to quality improvement in Industry 4.0, as it provides valuable insights into the performance, issues, and opportunities of the manufacturing processes. However, manual data collection and analysis can be time-consuming, error-prone, and inconsistent, leading to poor quality decisions and outcomes. By automating data collection and analysis, the MES can capture and process real-time and accurate data from various sources, such as sensors, machines, operators, or external systems, and provide timely and actionable feedback to the manufacturer. This way, the MES can help the manufacturer identify and resolve quality problems, optimize processes, and prevent defects.

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Fawn Parke

Head of Factory
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In the world of infinite data collection, be intentional about what critical control parameters you are gathering. MES should measure those which will specifically identify if the process is in control or not.

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3 Implement closed-loop quality control

The third step to implement MES-enabled quality control is to implement closed-loop quality control, which is a feedback mechanism that enables continuous improvement of the quality metrics. Closed-loop quality control involves four stages: plan, do, check, and act. In the plan stage, the manufacturer defines the quality objectives and metrics, and establishes the standards and procedures for achieving them. In the do stage, the manufacturer executes the planned actions and monitors the results through the MES. In the check stage, the manufacturer compares the actual results with the expected results, and identifies any gaps or deviations through the MES. In the act stage, the manufacturer implements corrective or preventive actions to close the gaps or deviations, and updates the standards and procedures accordingly through the MES.

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4 Integrate quality with other functions

The fourth step to implement MES-enabled quality control is to integrate quality with other functions, such as production, maintenance, inventory, logistics, or engineering. Quality is not an isolated activity, but a cross-functional one that affects and is affected by other aspects of the manufacturing operations. Therefore, to ensure consistent and holistic quality, the manufacturer needs to coordinate and align the quality objectives and metrics with the other functions, and share the relevant data and feedback through the MES. By integrating quality with other functions, the MES can help the manufacturer optimize the overall efficiency, productivity, and profitability of the manufacturing operations, and enhance the customer value and satisfaction.

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Jay Bronec

Data driven executive pushing for 1% better everday. Lifetime learner and new venture seeker - former part-time Fireman and United Airlines Ramp employee always looking for life hacks. Kolbe Fan (5383)
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Yes, MES-enabled quality control is better than the current state of most quality systems which is a silo where citizen developers do the best they can (usually relegated to excel) fundamental problem is that quality rarely gets connected to the IT/OT technology stack; this is the first step for improving quality systems results and helping these citizen developers add value.

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Gnaminin Kablan

Chemical & Process Engineering | ISMQ - QSE System Manager | PMI? Member | MBA | DBA | TOSA? DIGCOMP | GOOGLE PMP |
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Effectivement, l'intégration de la qualité est vitale pour un système d’exécution de fabrication (MES). Un MES avec gestion de la qualité intégrée surveille la ligne de production pour identifier les problèmes potentiels, afin de minimiser les retards et les erreurs de production. Les fabricants ont des exigences de contr?le de qualité plus strictes et des pressions plus fortes pour améliorer leur efficacité et réduire leurs co?ts. La gestion de la qualité intégrée au MES donne à ces entreprises les outils nécessaires pour mesurer les performances, améliorer l'expérience produit pour les clients, garantir la conformité, et bien plus encore.

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Fawn Parke

Head of Factory
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When integrating quality with other functions, gain buy-in by demonstrating the benefits. Look to design for quality upfront rather than relying on manual processes.

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5 Empower the workforce

The fifth step to implement MES-enabled quality control is to empower the workforce, which is the human element that plays a vital role in ensuring quality. The workforce includes the operators, technicians, supervisors, managers, and engineers who are involved in the quality control activities, such as planning, executing, monitoring, analyzing, or improving. To empower the workforce, the manufacturer needs to provide them with the necessary training, tools, and incentives to perform their quality tasks effectively and efficiently. The MES can support the workforce empowerment by providing them with easy access to the quality data and feedback, enabling them to perform self-inspections, audits, or corrections, and facilitating their collaboration and communication across the organization.

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6 Review and improve

The sixth step to implement MES-enabled quality control is to review and improve the quality objectives, metrics, and practices on a regular basis. Quality is not a static state, but a dynamic and continuous process that requires constant evaluation and enhancement. The manufacturer needs to review the quality performance and outcomes periodically, and identify the strengths, weaknesses, opportunities, and threats of the quality control activities. The MES can assist the review and improvement process by providing comprehensive and historical reports and dashboards that display the quality trends, patterns, and benchmarks. Based on the review and improvement process, the manufacturer can adjust and update the quality objectives, metrics, and practices to suit the changing needs and expectations of the customers and the market.

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Gnaminin Kablan

Chemical & Process Engineering | ISMQ - QSE System Manager | PMI? Member | MBA | DBA | TOSA? DIGCOMP | GOOGLE PMP |
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Grace à un MES, on peut visualiser la différence entre la situation actuelle et les objectifs convenus, ainsi que la propagation des indicateurs visuels et autres nécessaires pour établir et maintenir une culture d'amélioration continue. Par exemple, le temps passé auparavant par les travailleurs et les responsables des opérations à préparer des rapports peut être considérablement réduit en utilisant un MES pour capturer des informations en temps réel. De plus, en collectant et en analysant des données, telles que le montant de la perte, l’heure, l’état de l’occurrence et d’autres paramètres potentiellement pertinents, on peut déterminer efficacement la cause du problème.

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Gnaminin Kablan

Chemical & Process Engineering | ISMQ - QSE System Manager | PMI? Member | MBA | DBA | TOSA? DIGCOMP | GOOGLE PMP |
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Dans cette nouvelle usine où les humains et les machines collaborent tout au long des lignes de production 4.0. Le travail sera ainsi optimisé et amélioré en continue pour une excellente qualité des produits.

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What are the best MES-enabled quality control practices in Industry 4.0?

1

2

3

4

5

6

7

1 Define quality objectives and metrics

2 Automate data collection and analysis

3 Implement closed-loop quality control

4 Integrate quality with other functions

5 Empower the workforce

6 Review and improve

7 Here’s what else to consider

Manufacturing Operations

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What are the best MES-enabled quality control practices in Industry 4.0?

1

2

3

4

5

6

7

1 Define quality objectives and metrics

2 Automate data collection and analysis

3 Implement closed-loop quality control

4 Integrate quality with other functions

5 Empower the workforce

6 Review and improve

7 Here’s what else to consider

Manufacturing Operations

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