Quality Control Software for Manufacturing

June 20, 2024

Quality control has long been an essential element of manufacturing quality management. What is different today are the new pressures manufacturers are facing, including a growing shortage of skilled labor and tighter profit margins. Yet ensuring your company consistently manufactures high-quality products is essential for success.

Quality control software is an easy way for manufacturers to maintain consistent quality with greater efficiency and less waste. By investing in quality control software, manufacturing companies can not only meet, but exceed their quality objectives, leading to greater customer satisfaction, reduced costs and a stronger competitive position in the marketplace. This article explores the primary features of manufacturing quality control software and why manufacturers should utilize it as part of a comprehensive, automated quality management system (eQMS).

What is quality control software for manufacturing?

Quality control in manufacturing is a subsystem of quality management that focuses on inspections. These inspections occur at various stages of production or delivery in order to ensure a product or service conforms to established specifications and is of consistent and acceptable quality.

Quality control software for manufacturing supports those efforts by automating and integrating quality control tasks, such as document control, change control and corrective actions. It enables companies to more easily meet regulatory mandates and comply with industry standards by providing a centralized, systematic process for quality control and assurance. Quality control is an integral part of quality management system software with many eQMS applications supporting quality control efforts.

What is the difference between quality control and quality assurance?

If you’re not familiar with quality processes, the terms and acronyms can be a bit confusing. One of the most common misconceptions involves the difference between quality control (QC) and quality assurance (QA). Though these two terms are often used interchangeably, they actually are different parts of the quality management process.

Quality assurance focuses on defining standards for all stages of the product’s lifecycle, from design to packaging to marketing. The American Society for Quality defines quality assurance as “all the planned and systematic activities implemented within the quality system that can be demonstrated to provide confidence that a product or service will fulfill requirements for quality.”

Essentially, quality assurance is the planning, testing and monitoring parts of a quality management plan that ensure the product is ready to be manufactured. Quality control is the inspection portion of quality management, designed to ensure that a product is safe and effective after production.

The manufacturing quality control process

Quality control processes differ depending on the product being manufactured and the regulations to which it is subject. In general, the quality control process follows the steps outlined below.

1. Determine Standards

Before you can assess quality, you must first develop specifications to measure against. These should be measurable attributes and include any requirements outlined by government agencies, customers or industry standards. General Manufacturing Practice (GMP) standards and the International Organization for Standardization’s (ISO) ISO 9001 are the two most utilized sets of manufacturing standards.

2. Select a Quality Control Method

Your quality standards, product and industry will help determine what quality-control method best suits your operations. There are many quality control methods. Some of the most common methods include:

Acceptance sampling – A sample is chosen randomly for inspection, and batches are accepted or rejected based on the inspection’s outcome.
Six Sigma –Statistical methods are used to achieve a level of quality that equates to only 3.4 defects per million. Six Sigma uses the DMAIC approach (Define, Measure, Analyze, Improve, Control) to identify and eliminate causes of variation.
Statistical Process Control – This method controls quality by monitoring and measuring manufacturing processes, using data collected to ensure the process is performing optimally.
Total Quality Management (TQM) – This approach relies on the entire organization to be part of monitoring and improving processes and products, and prioritizes customer satisfaction and feedback.

3. Establish Procedures & Train Staff

Build procedures that support the quality control method you have selected, detailing what to do when defects are identified. Train quality control staff to ensure inspection process alignment and consistency.

4. Conduct Testing

After you’ve determined a sample size to be tested, choose the batch and number of products to test, and measure each item against your quality standards. At this point, quality is approved or rejected.

5. Analyze

If defects are discovered, analyze any deviations and determine the root cause.

6. Take Appropriate Action

Determine whether to reject, test again, make repairs or halt production. The final course of action will depend on your root cause analysis.

How does manufacturing quality control software work?

A robust eQMS addresses all of the key components of quality control in manufacturing. These typically include document control, inspection, testing, sampling, data analysis, corrective actions, supplier management and audit/compliance.

Inspections and testing

Inspection applications in an eQMS allow for the creation and execution of testing and inspection plans. Users are able to configure processes to their specifications so that inspections are triggered according to set parameters.

Users can use the software to plan, schedule and communicate about inspections both internally and externally. Various testing methods are accommodated by the software, with all data centralized and organized for easy access and shareability. Inspection and test results are easily tracked and recorded for traceability and compliance.

Nonconformance management

An eQMS allows for the consistent monitoring of manufacturing processes and outputs against established criteria, helping to identify and evaluate nonconformances, and providing tools for recording, assigning and monitoring progress toward closure.

Document control

Document control is an essential feature of manufacturing quality control software. An eQMS provides a centralized repository for all quality documentation, from word processing files to CAD drawings, photos and spreadsheets. Automatic version control, approval routings and electronic signature capabilities assist in keeping manufacturing quality control efforts on track.

Supplier management

Manufacturers can also utilize an eQMS to manage materials and components supplied by third parties. Supplier management software centralizes supplier information in one, web-based system where organizations can track the status of supplier performance and communicate with them about related tasks, such as corrective actions. The software provides a platform to streamline all of the tasks that make up a business’ relationship with a supplier, including onboarding, documentation, performance evaluations, corrective actions and surveys.

Compliance management and traceability

An eQMS facilitates every stage of the audit process, from planning and scheduling to generating final reports, improving the efficiency and accuracy of the audit process. It automates the process of preparing and executing audits by helping companies analyze data, assess risks, track issues, report results and centralize documentation. Regulatory compliance is streamlined and simplified with centralized workflows and full traceability.

Reporting and Analytics

Effective quality control relies on comprehensive data analysis. Quality control software offers robust reporting and analytics tools that provide insights into quality trends, process performance and areas for improvement. This data-driven approach enables continuous improvement and informed decision-making.

Benefits of investing in quality control software for manufacturing

No one likes a recall. Not the consumer, the retailer, and especially not the manufacturer. One of the best way to avoid quality situations like a recall is to create a culture of quality centered around your quality management system. An eQMS facilitates this by being a hub for all quality efforts, mitigating risk, automating details and standardizing processes.

Centralized, accurate data

Manufacturing quality control software provides a centralized system for managing all necessary documentation, from inspection records to nonconformance reports. This ensures that companies can provide the required evidence to demonstrate compliance during audits and inspections.

Compliance framework

Manufacturing quality control software provides a built-in framework for regulatory compliance, helping to ensure that all documents are complete and available. Most eQMS offer templates that can be used as-is or configured to meet a manufacturer’s unique needs. Actions are tracked and easily traceable.

Mitigate risk

Quality control software includes tools for risk assessment and mitigation, helping organizations identify potential risks and implement effective controls. Not only is the risk of noncompliance diminished, quality control software can help to identify and correct defects early, reducing necessary rework, minimizing waste and lowering production costs.

Operational efficiency

Automated quality control processes are faster and more accurate than manual inspection processes. This leads to significant time savings and allows employees to focus on more strategic tasks. Software can identify bottlenecks in the review process and inefficiencies in production, enabling companies to optimize operations.

Data-driven actions

Real-time data, combined with the reporting and analytics features available with quality control software, can provide valuable insights into production processes and quality trends. A data-driven approach enables companies to make more informed decisions that support continuous improvement initiatives. By discovering root causes of quality issues, companies can take proactive measures to prevent future problems.

Improved supplier relationships

Quality control software offers applications that can help your business build strong supplier relationships. Supplier management applications streamline processes, automate tasks and provide end-to-end visibility into supplier performance for better risk control, communication and regulatory compliance. QT9 QMS offers a supplier portal, which enables two-way communication and document sharing, allowing suppliers to more easily partner with your organization.

Stay competitive

Technological innovations are rapidly changing the look of manufacturing. Investing in an eQMS with quality control software will help your company maintain a competitive edge by more easily and efficiently addressing the quality process that keep you producing consistently high-quality products.

Customer satisfaction

High-quality products lead to higher customer satisfaction. By ensuring that products meet or exceed customer expectations, companies can build stronger relationships with their customers and enhance their brand reputation. Satisfied customers are more likely to become repeat buyers and recommend your products to others.

Summary

In today’s environment, manufacturers need the competitive edge and improved accuracy of software solutions. Automating and integrating key quality control tasks with software, like QT9 QMS, enhances overall operational efficiency, reduces waste and simplifies regulatory compliance.

What’s more, QMS software provides manufacturers with real-time quality-control data, allowing them to make more informed decisions that can impact a company’s bottom line. Centralizing data, facilitating compliance and enabling data-driven decision-making, leads to higher customer satisfaction and a stronger brand reputation.

QT9 QMS is a total quality solution available at an accessible price point, with 25-plus standard modules that help simplify and centralize quality and compliance. Plus, QT9 offers full customer support, an ERP integration and a Business Intelligence tool to help visualize and make informed decisions.