MPDV: In-production inspection (CAQ) with HYDRA by MPDV

In-Production Inspection with HYDRA FEP

Application & benefits
Quality inspection and production processes in one system!
Quality assurance requirements have constantly increased over the years and continue to do so. Not only do these requirements ensure that products are manufactured at a specific quality grade but they also serve to permanently monitor and improve process quality. With the HYDRA In-Production Inspection module (FEP), quality assurance is an integrated process that runs in tandem with production management. The use of HYDRA FEP prevents redundant data storage in multiple systems. CAQ functions that are seamlessly integrated in an MES also provide a complete view - from goods receipt and through the entire manufacturing process to goods issue.
HYDRA FEP supports inspection planning, operator self-testing and determination of the usage decision. Additionally, evaluations of test results help identify trends and errors in the process at an early stage. HYDRA FEP detects causes of errors and identifies specific measures to help eliminate them before they occur by supporting a closed-loop process. This leads to a reduction of scrap related costs.
Benefits of in-production inspection with HYDRA FEP
Greater reliability without additional effort and expense due to automatic calculation of inspection due dates
Improved visibility of accumulated scrap reasons to identify root causes
Less effort for staff as only one system manages production and CAQ
Complete transparency of all quality inspections
Robust process quality through proactive management of quality issues
Lower production costs through reduction of scrap and rework
Many business units across the enterprise can benefit from an MES system such as HYDRA. Our ROI Analyzer reveals the untapped potentials that are still hidden within your production processes and will show you how they can be assessed monetarily.
Highlights
State-of-the-art quality assurance with MES
HYDRA FEP combines many important CAQ functions and covers the entire spectrum - from quality planning and data collection to the evaluation of test results. The recording and information functions of in-production inspection and statistical process control (SPC) can be used together with other applications such as HYDRA Shop Floor Data (BDE) and HYDRA Machine Data (MDE) at the same shop floor terminals with integrated user dialogs:
Integrated inspection planning including interfaces to the high level ERP or QM system
Flexible definition of characteristics and due dates
Intuitive inspection data collection directly at the shop floor terminal, at inspection stations or with smartphone or tablet
Automatic transfer of measured values from digital measuring devices and complex measuring machines, and the use of continuous data streams (process data collection)
Detailed evaluations, diagrams, control charts and reports (also on mobile devices) and the creation of test certificates
Integrated functions used in goods issue, for the initial sample inspection and the production control plan
Additionally, HYDRA FEP can be tightly integrated with other HYDRA applications. Examples include:
Shop floor data collection
Machine data collection
Process data
Tracking & Tracing
Premium and incentive wages
Material and product logistics
Tool and resource management
Test equipment management
As with all HYDRA applications, we offer targeted training courses in order to make the implementation of the system as efficient as possible. In the training courses you will learn how to conveniently integrate your requirements into the system.
Functions
Firm grip on quality
With demand-driven planning functions, flexible collection functions and numerous evaluations, HYDRA FEP ensures comprehensive transparency that is appreciated by both machine operators, plant operators and QA managers. Due to the close relationship between HYDRA FEP, the areas of goods issue, initial sample inspection and production control plan have also been integrated into the system.

Quality planning
With HYDRA FEP, inspection plans can either be created in the application itself or transferred from a master system (e. g. ERP). Inspection plans apply for single articles or entire article groups depending on the configuration. A number of options are available to the user.
Example functions

Flexible definition of characteristics (variable, attributive, visual defect recordings, inspection charts, random samples)
Specification of tolerance and action limits and plausibility clauses
Specification of intervals, events or due dates for inspections after production, following a certain number of cycles or status change, etc.
Requirements for measures
Collection of inspection data
HYDRA FEP offers ergonomic and intuitive recording functions in order to ensure acceptance by the operator or inspector. The willingness to work with the system guarantees that the data is maintained properly.
Example functions

Intuitive recording of variable and attribute features or error collection cards also with smartphones or tablets
Automatic entry of measured values using digital measuring equipment (sliding caliper, dial gauge, outside micrometer)
Transfer of automatically collected process data
Display of contextrelated test instructions, documents and control charts at the shop floor terminal
Specific dialogs for sampling and inspection stations in the QA lab
Evaluation of the inspection results
To establish a control loop to improve process quality, the measured values and test data must be prepared and visualized. In addition, HYDRA FEP offers control charts and evaluations with powerful filter functions.
Example functions

Configurable control charts (XQuer chart, pchart, single value chart, R-chart, s-chart, Median chart and histograms)
Failure mode analysis using Pivot functions
Machine, order, article, lot and inspection points relating to evaluations
Statistical evaluations of individual cavities for multicavity molds (e. g. for injection molding processes)
Data export for common statistical programs (e. g. qsSTAT®)
Functions for goods issue
Many functions of in-production inspection are also relevant for goods issue. Inspection plans specifically generated during goods issue are used.
Example functions

Inspection of inventory goods
Use of already defined characteristics
Creating individual inspection certificates based on MS Office templates
Initial sample inspection
The initial sampling defines product and quality characteristics before an article goes into volume production and are agreed upon between customer and supplier. This agreement minimizes quality cost and risks for both parties.
Example functions

Assigning documents and storage of scanned documents (e. g. drawings, pictures, videos)
Manual and automatic collection of inspection data
Preparing and managing initial inspection reports based on MS Office templates
Transfer of the initial sample inspection plan to the production inspection plan after its release
Production control plan
Inspection plans, methods, characteristics and the test equipment used can be compiled in a global production control plan in order to comply with standards like QS 9000 or TS 16949. HYDRA ensures that only authorized employees make changes. The system also safeguards that changes are versioned accordingly and that approvals are managed.
Example functions

Revision control management of production control plans
Specifying team members and release notes
Assigning any documents to the integrated document list
MS Office form compatibility including integrated designer for specific changes
Display of specific requirements
Because every manufacturing company has unique requirements, HYDRA FEP offers customized configuration options, while still being able to take advantage of a standard software implementation.
Further details

HYDRA FEP can be configured via extensive master data and flexible settings without the need for custom programming:
Specifying any failure types, location and causes
Configurable characteristics that calculate their own values
Creating inspection points by event due with automatic generation of inspection decisions
Using HYDRA FEP to simply collect data as a QM subsystem
Transfer of master data from master systems (e. g. SAP QM)
Flexible configuration of control charts including monitoring functions such as trend, run, middleThird, etc.
Integration of inspection procedures with the option to design a dialog
Configurable workflow to collect quality data from failures and measures
In HYDRA FEP modern development tools are available to the user for a more detailed personalization in the form of customer-specific functions and evaluations.
Production inspection in tandem with many other MES applications
HYDRA FEP integrates seamlessly into the network of many production-related functions, providing important current data from production and accessing the results of other applications.
Further details

Integration into shop floor and machine data collection
Inspection plans and characteristics focused on the production process, e.g. linking production orders or plans
Direct assignment of inspection steps for operations
Automatic monitoring of defined due dates for inspection events using collected machine data (e. g. quantity, machine status, production time)
Standardized operation functions for order, quality and machine data at shop floor terminals and PCs in production
Integration into process data collection
Using automatically collected process values for quality inspection
Integration into material management and Tracking & Tracing
Linking a quality inspection with the control of material flow (e. g. when material is blocked in the event that it failed)
Providing measured values and inspection results to document production processes or traceability
Integration into premium and incentive wages
Providing KPIs (e. g. scrap rate) to factor in performancerelated wages
Integration into tool and resource management and test equipment management
Order, quality, machine and tool data is crossreferenced (e. g. inspection relating to cavities)
Use of inspection equipment that is managed, monitored and calibrated in the MES

Application & benefits

Quality inspection and production processes in one system!

Quality assurance requirements have constantly increased over the years and continue to do so. Not only do these requirements ensure that products are manufactured at a specific quality grade but they also serve to permanently monitor and improve process quality. With the HYDRA In-Production Inspection module (FEP), quality assurance is an integrated process that runs in tandem with production management. The use of HYDRA FEP prevents redundant data storage in multiple systems. CAQ functions that are seamlessly integrated in an MES also provide a complete view - from goods receipt and through the entire manufacturing process to goods issue.

HYDRA FEP supports inspection planning, operator self-testing and determination of the usage decision. Additionally, evaluations of test results help identify trends and errors in the process at an early stage. HYDRA FEP detects causes of errors and identifies specific measures to help eliminate them before they occur by supporting a closed-loop process. This leads to a reduction of scrap related costs.

Benefits of in-production inspection with HYDRA FEP

Greater reliability without additional effort and expense due to automatic calculation of inspection due dates
Improved visibility of accumulated scrap reasons to identify root causes
Less effort for staff as only one system manages production and CAQ
Complete transparency of all quality inspections
Robust process quality through proactive management of quality issues
Lower production costs through reduction of scrap and rework

Many business units across the enterprise can benefit from an MES system such as HYDRA. Our ROI Analyzer reveals the untapped potentials that are still hidden within your production processes and will show you how they can be assessed monetarily.

Highlights

State-of-the-art quality assurance with MES

HYDRA FEP combines many important CAQ functions and covers the entire spectrum - from quality planning and data collection to the evaluation of test results. The recording and information functions of in-production inspection and statistical process control (SPC) can be used together with other applications such as HYDRA Shop Floor Data (BDE) and HYDRA Machine Data (MDE) at the same shop floor terminals with integrated user dialogs:

Integrated inspection planning including interfaces to the high level ERP or QM system
Flexible definition of characteristics and due dates
Intuitive inspection data collection directly at the shop floor terminal, at inspection stations or with smartphone or tablet
Automatic transfer of measured values from digital measuring devices and complex measuring machines, and the use of continuous data streams (process data collection)
Detailed evaluations, diagrams, control charts and reports (also on mobile devices) and the creation of test certificates
Integrated functions used in goods issue, for the initial sample inspection and the production control plan

Additionally, HYDRA FEP can be tightly integrated with other HYDRA applications. Examples include:

As with all HYDRA applications, we offer targeted training courses in order to make the implementation of the system as efficient as possible. In the training courses you will learn how to conveniently integrate your requirements into the system.

Functions

Firm grip on quality

With demand-driven planning functions, flexible collection functions and numerous evaluations, HYDRA FEP ensures comprehensive transparency that is appreciated by both machine operators, plant operators and QA managers. Due to the close relationship between HYDRA FEP, the areas of goods issue, initial sample inspection and production control plan have also been integrated into the system.

Quality planning

With HYDRA FEP, inspection plans can either be created in the application itself or transferred from a master system (e. g. ERP). Inspection plans apply for single articles or entire article groups depending on the configuration. A number of options are available to the user.

Example functions
Flexible definition of characteristics (variable, attributive, visual defect recordings, inspection charts, random samples)
Specification of tolerance and action limits and plausibility clauses
Specification of intervals, events or due dates for inspections after production, following a certain number of cycles or status change, etc.
Requirements for measures

Collection of inspection data

HYDRA FEP offers ergonomic and intuitive recording functions in order to ensure acceptance by the operator or inspector. The willingness to work with the system guarantees that the data is maintained properly.

Example functions
Intuitive recording of variable and attribute features or error collection cards also with smartphones or tablets
Automatic entry of measured values using digital measuring equipment (sliding caliper, dial gauge, outside micrometer)
Transfer of automatically collected process data
Display of contextrelated test instructions, documents and control charts at the shop floor terminal
Specific dialogs for sampling and inspection stations in the QA lab

Evaluation of the inspection results

To establish a control loop to improve process quality, the measured values and test data must be prepared and visualized. In addition, HYDRA FEP offers control charts and evaluations with powerful filter functions.

Example functions
Configurable control charts (XQuer chart, pchart, single value chart, R-chart, s-chart, Median chart and histograms)
Failure mode analysis using Pivot functions
Machine, order, article, lot and inspection points relating to evaluations
Statistical evaluations of individual cavities for multicavity molds (e. g. for injection molding processes)
Data export for common statistical programs (e. g. qsSTAT®)

Functions for goods issue

Many functions of in-production inspection are also relevant for goods issue. Inspection plans specifically generated during goods issue are used.

Example functions
Inspection of inventory goods
Use of already defined characteristics
Creating individual inspection certificates based on MS Office templates

Initial sample inspection

The initial sampling defines product and quality characteristics before an article goes into volume production and are agreed upon between customer and supplier. This agreement minimizes quality cost and risks for both parties.

Example functions
Assigning documents and storage of scanned documents (e. g. drawings, pictures, videos)
Manual and automatic collection of inspection data
Preparing and managing initial inspection reports based on MS Office templates
Transfer of the initial sample inspection plan to the production inspection plan after its release

Production control plan

Inspection plans, methods, characteristics and the test equipment used can be compiled in a global production control plan in order to comply with standards like QS 9000 or TS 16949. HYDRA ensures that only authorized employees make changes. The system also safeguards that changes are versioned accordingly and that approvals are managed.

Example functions
Revision control management of production control plans
Specifying team members and release notes
Assigning any documents to the integrated document list
MS Office form compatibility including integrated designer for specific changes

Display of specific requirements

Because every manufacturing company has unique requirements, HYDRA FEP offers customized configuration options, while still being able to take advantage of a standard software implementation.

Further details
HYDRA FEP can be configured via extensive master data and flexible settings without the need for custom programming:
Specifying any failure types, location and causes
Configurable characteristics that calculate their own values
Creating inspection points by event due with automatic generation of inspection decisions
Using HYDRA FEP to simply collect data as a QM subsystem
Transfer of master data from master systems (e. g. SAP QM)
Flexible configuration of control charts including monitoring functions such as trend, run, middleThird, etc.
Integration of inspection procedures with the option to design a dialog
Configurable workflow to collect quality data from failures and measures
In HYDRA FEP modern development tools are available to the user for a more detailed personalization in the form of customer-specific functions and evaluations.

Production inspection in tandem with many other MES applications

HYDRA FEP integrates seamlessly into the network of many production-related functions, providing important current data from production and accessing the results of other applications.

Further details
Integration into shop floor and machine data collection
Inspection plans and characteristics focused on the production process, e.g. linking production orders or plans
Direct assignment of inspection steps for operations
Automatic monitoring of defined due dates for inspection events using collected machine data (e. g. quantity, machine status, production time)
Standardized operation functions for order, quality and machine data at shop floor terminals and PCs in production
Integration into process data collection
Using automatically collected process values for quality inspection
Integration into material management and Tracking & Tracing
Linking a quality inspection with the control of material flow (e. g. when material is blocked in the event that it failed)
Providing measured values and inspection results to document production processes or traceability
Integration into premium and incentive wages
Providing KPIs (e. g. scrap rate) to factor in performancerelated wages
Integration into tool and resource management and test equipment management
Order, quality, machine and tool data is crossreferenced (e. g. inspection relating to cavities)
Use of inspection equipment that is managed, monitored and calibrated in the MES