Smart Quality is key in a connected industry

Manufacturing processes such as welding and stamping can be unstable and reach high rates of rework and even scrap and, therefore, reducing these rates will significantly increase productivity and reduce costs.

Artificial Intelligence applied to quality control

To achieve this improvement, Tecnomatrix, through and its Intelligent Quality System (IQS), proposes to implement real-time control and digitalization systems, artificial intelligence algorithms to achieve preventive systems and the integration of blockchain technology in order to guarantee the inviolability of data. This set of technological solutions accelerates the achievement of Quality 4.0 or Smart Quality and leads the way towards zero-defect manufacturing.

To achieve this goal, includes real-time data-visualization and decision-making tools, thanks to the digitization and integration of all the quality-related data, irrespective of whether the source is manual or machine-generated and regardless of the process from which it is collected, from audits to laboratory tests or cosmetic end-of-line controls.

In addition to analyzing real-time data, to achieve zero-defect manufacturing and foresee potential costs, machine learning algorithms are needed. For instance, they can be implemented to clustering all collected data and to apply predefined recipes based on artificial intelligence to improve and correct the manufacturing process. Consequently, adding value to quality data and creating self-correcting predictive systems which alert us from potential incidents.

Smart Quality Dashboard

Improvements in quality, and specifically its evolution towards an intelligent quality, must ensure data traceability and data integrity. In, the application of Blockchain technology ensures data integrity in key processes such as quality walls, as well as through Smart Contracts to validate the agreements between supplier and provider.

The present and future of the Intelligent Quality or Quality 4.0 must include the digitalization of control processes, the collection and integration of all data, the application of artificial intelligence in quality-management systems and the implementation of blockchain technology, to achieve zero-defect manufacturing.

Report sharing: sharing information is key

Report sharing, compartir información es la clave

In a recent article about Metrological reports 4.0., we reviewed the benefits that can be achieved if we move from hard-copy reports to a digital and analytical tool, which will make and automatically update every report

  • updated summary of the quality status of each project and part;
  • cross-data analysis, regardless of the source;
  • a combination of different types of graphics;
  • without restrictions in the types of checks in the same report: Numerical, Boolean or a list displaying several options to choose;
  • filtering results (by date, machine, etc.).

Now imagine that you are an OEM that is receiving the data regularly (Daily?  Weekly?) from your Tier1 suppliers. The gap between reports is long enough to risk that the process turns out of tolerances, or even take place, so that any decision taken thereafter will be extremely expensive, based on the urgency of the moment.

Report sharing
Report Sharing

However, what if we could have this type of reports always available, and the data being updated in real-time?

What would happen if, besides creating dynamic reports, with data from multiple sources and reviewing different types of instantly updated checks, it would be possible to share them in real time? Would that provide us a guarantee about the quality status of the parts we receive?

Obviously, the answer is yes. A platform like offers the possibility to share every report in real time in a simple way, through the report sharing feature, reviewing updated data and according to the measures determined in the control plans. This way, up-to-the-minute information will be available after being validated by the Tier1 supplier. This will allow continuous monitoring of the process and taking informed and data-based decisions.

The digital transformation implies that clients and suppliers work in collaborative environments where information sharing is a key pillar to ensure the quality of processes and to avoid inefficiencies and unnecessary costs.

Connected Process, Smart Decisions

Connected Process

We live in the Big Data era. It is said that data is like the oil or “black gold” of the 21st century. However, capitalizing on data seems overly complicated and unachievable, only reachable for leading teams of experts. Many people believe that their company is not ready to enter this domain but, is it true?

Data-based decisions

Do you remember when Google, after analyzing 50 million search terms, was able to quickly predict the outbreak of a new virus in 2009? Or when a company from the automotive sector such as Mercedes solved, through a contest in Kaggle, the prediction of testing time in highly personalized cars?

The truth is that these examples may seem remote and inaccessible, achieved by large and specialized IT teams looking for innovative solutions. However, related to a Big Data study, we can also find a cafeteria in Edinburgh that, through an easy analysis of cash data, was able to detect off-peak hours and purchasing patterns. They repositioned products and changed opening hours, resulting on large savings and increased benefits.

So, how can we take advantage of Big Data analysis in quality departments? Can we do like the cafeteria and get small large improvements? The answer is certainly YES, and without doing anything very different from what we are already doing. It is about starting with a good use case.

First, we need to start by asking some questions and defining what we want to know, and then start looking for the answers to make the right decisions. After a short analysis, we can see that several processes and actions already collect quality-related data, even before manufacturing begins, and in different departments.

Connected Processes: Smart Quality

Once we know data availability and how to collect it, applying a digital solution like will allow digitizing all those processes that are key to evaluate the ROI. Some of the applications that will show quick results are:

  • Implementing cosmetic control in an EOL (end of line) will showcase the value of answering in real time questions such as: which areas produce more defects, which defects occur more often, which defects are more severe, etc.
  • Setting up patterns of digital control in a process with an already available computer and/ or measuring with Bluetooth instruments and upload the data automatically to will ensure operators to be more informed, more accurate and traceable data, and enable quick and multidimensional analysis by date, attributes, sample status, daily activity…
Control Guide: Dynamic Report
Control Guide: Feature Selection
Control Guide: Bluetooth measurements

In summary, these are only some of the advantages that are achievable with a solution like Let’s review in other blog entries some other aspects such as, for instance, the benefits of digitalizing processes like audits, control instruments or incident management.

Defect mapping: visual control in quality

Can you imagine being able to report the quality of products and their defects easily, efficiently and quickly? will help you to achieve this by means of our defect mapping module.

Defect Mapping on a door
Defects visualization on a heatmap

Defect mapping is an innovative functionality that allows you to control and visualize the quality status in an agile and efficient way, which contributes to an early correction of faults and a more preventive decision-making process, resulting in significant non-quality cost savings.

How does defect mapping work?

Defect mapping lets you size the grid and image according to the required level of accuracy, setting it up to meet the product’s needs and requirements.

Defect mapping set up

Via this process of quality control, defects will be easily located on the screen, as well as their severity, thus obtaining a heatmap where the intensity of defects and severity is shown.

As the defects and its severity are reported, the heatmap, trend and Pareto charts will be updated. The heatmap, together with the alarm and notification system, will empower quick decision-making and reduce costs due to poor product quality.

Activity and Control Charts on

Defect mapping is a solution within the natural evolution towards Industry 4.0 that integrates and provides access in one platform to quality data coming from several sources.

Complementary Pareto to defect mapping guarantees real time data collection and transforming it into information to speed up decision-making. Amongst other features, we launched for all our customers an innovative feature such as defect mapping with a large impact on the reduction of non-quality costs.