The Innova Quality Control module allows quality personnel to enter quality related information at designated control points throughout the production process, removing the need for paper and pen. The new generation of the QC module contains a number of new features that make the QC manager’s life easier and improve the data collection process.
New features include:
The Inspection viewer allows the user to browse the quality data entered at the different control points throughout the factory. It can also be used to edit and validate data and has uses in laboratory settings when it comes to entering inspection results into the system.
The database automatically logs all entries and changes to entered data. The full history of data changes is available through the Inspection viewer for each individual inspection.
It is now possible to start an inspection, save it, and continue with it at a later time or in a different location. For example, when inspecting a frozen product, the first part of the inspection can be performed while the product is still frozen, and completed after it has been thawed out. Another example is a bacterial test where the inspection begins when the swab is first taken, and is completed in the laboratory when the samples have been processed.
A new Offline inspection client allows the user to perform multiple inspections while outside network range. The offline client runs on any Windows 8 tablet and is ideal for situations where network coverage cannot be guaranteed at all inspection points. All the inspection data is automatically uploaded to the Innova server as soon as the device finds the network.
Non-conformities can now be entered into Innova as standalone registrations as well as in response to a failed inspection. Non-conformities can be maintained from an office interface. The system also includes non-conformity reports.
The End-user report designer included with the QC module is an easy-to-use designer that provides the ability to modify standard Innova reports as well as create new reports from scratch.
Registration requirements and inspection lists differ greatly between factories and industries. The End-user report designer solves the problem of creating standard reports that meet the differing reporting requirements of quality managers.
Another new way to harvest information from the quality registrations is through dashboards. The dashboards display up-to-the-minute information, so as soon as an inspection is entered into the system on the floor, the relevant information is available on the quality manager’s screen in the office. Two different dashboard components are available: one that shows the trend of an inspection item and another that shows quantitative information about inspections performed that day.
The quality manager can schedule inspections for the day or week, based on the planned production. Repeated but infrequent inspections can also be entered into the inspection calendar to ensure they are not forgotten. The system notifies the quality manager automatically of any planned inspections that have not been performed within the given time limit.
QC now provides camera support. Any web-cam supported by Windows can be connected to the IPC to add images to inspections.
Non-conformity registrations can also contain images added in the same way.
The Offline client supports any cameras built into the tablet device.
The previous version provided a simple response mechanism based on a score that was calculated from the inspections. Now it is also possible to provide responses based on single values in the inspection. For example, if the temperature is out of bounds, it can trigger a response even if no score is calculated for the inspection.
Four new response types have been added that can be used both as a response to a failed inspection and to a value being out of bounds:
Any number of these response types can be combined to create a set of responses required when a product does not meet requirements. For example, if the temperature of incoming raw material is too high to take directly into production, a set of responses can be created that put the lot on hold and schedule a new inspection two hours later. That inspection would then have a response to remove the lot from hold.
Support has been added for the new A600 grader in the Innova Grading module. All parameters that can be set within the user interface on the grader are supported. The algorithms or batching modes available are:
This grader can be used with the existing grader control form, dashboard components, process unit controls and reports. Run-time weight range adjustments can also be performed on individual grades. This is accessible in the same manner as for the other graders, either via the Grades tab in the Grader control form or using the Grades dashboard control. Programs can be imported from or exported to the grader via the Grading programs form.