Elevating Quality Assurance with MES and Real-Time Process Monitoring

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Leveraging MES and real-time process monitoring for Smarter Decision-Making

The pressure to deliver flawless products, optimize costs, and satisfy customer demands is immense, but small and midsize manufacturing companies often struggle to maintain rigorous quality standards. Too often, these factories still rely on traditional, reactive quality assurance methods, often catching issues late in the production cycle. This approach not only increases the risk of defective products; it adds unnecessary waste and inefficiencies. By leveraging a manufacturing execution systems (MES) and real-time process monitoring, manufacturers can transform quality assurance from a reactive task into a proactive practice.

Here’s how an MES unlocks greater quality control with precision, efficiency, and actionable insights.

Traditional Quality Assurance Challenges

Conventional quality assurance methods often rely on end-of-line inspections. While this approach catches defects before products reach customers, it has significant drawbacks:

  1. Late Detection – If quality issues are rooted in the manufacturing process, detecting them after production only highlights the symptom, not the cause, leading to repetitive defects.
  2. Unnecessary Waste – Parts produced out of specification are scrapped or reworked, wasting valuable time, materials, and resources.
  3. Disjointed Insights – Without real-time data to link issues back to specific operations, adjustments often depend on guesswork rather than evidence, prolonging problem resolution.

Real-time process monitoring, enabled by an MES, addresses these shortcomings by embedding quality control into the manufacturing cycle.

Real-Time Process Monitoring and Why It Matters

MES systems provide a centralized platform for monitoring machine and process parameters as parts are being produced. Instead of waiting for final inspections, manufacturers can ensure that parts meet specifications throughout the production cycle. This proactive approach benefits quality assurance in a number of ways:

  1. Monitoring Parameters Against Specifications
    At the heart of real-time process monitoring is the ability to continuously compare production metrics against predefined “recipes.” For instance, in injection molding, critical parameters like barrel temperature, clamping pressure, and injection time are continuously tracked. If an MES detects deviations from acceptable thresholds, it triggers alerts, allowing line operators to intervene immediately.Consider the example of an injection molding machine that starts producing parts with slight dimensional defects. Traditional methods would catch these errors only during post-production audits. However, an MES and real-time process monitoring can identify this issue earlier by linking dimensional inconsistencies to fluctuating barrel temperatures, helping teams address root causes before more defective parts are made.
  1. Reducing Dependence on Manual Inspections
    Automated monitoring reduces human errors in inspection processes. The MES ties data from machines to parts, giving managers confidence that every unit produced adheres to quality standards. This approach not only saves time but also allows staff to focus on higher-value tasks rather than routine inspections.
  1. Detecting Trends and Preventing Failures
    An MES goes beyond spotting individual defects and to identify trends over time. For example, changes in vibration levels on a stamping machine may not lead to defects immediately but could signal worsening conditions. Addressing the issue at this early stage prevents serious operational disruptions and quality failures.
  1. Holistic Data Integration for Quality Analysis
    An MES connects shop floor data with enterprise-level systems, such as enterprise resource planning (ERP) to provide a comprehensive view of the production process, linking quality issues with associated jobs, materials, or even operators. Such integration enables manufacturers to dig deeper into recurring problems and refine production strategies over time.

Enhancing Quality with MES in Action

Manufacturers applying an MES for quality assurance report impactful results. Here are three practical scenarios showcasing the benefits:

  1. Tool Monitoring in Stamping Operations
    A metal stamping shop uses its MES to track pressure variation during processes. If the system detects unusual force during tooling, it signals potential die wear or misalignment. Immediate checks prevent off-spec products and extended downtime for tool rebuilding.
  2. Scrap Reduction in Plastics Manufacturing
    An MES tracks cushion position during plastics injection molding. If cushion levels deviate due to wear in the screw or barrel, the MES notifies the team, enabling corrective maintenance before scrap rates spike. This helps reduce waste and maximizes machine productivity.
  3. Vibration Alerts for High-Precision Machining
    By monitoring vibration patterns, the MES safeguards against subtle issues that can lead to defects. When excessive vibrations signal a potential problem with machine alignment, adjustments can be scheduled during planned downtime, ensuring quality work continues uninterrupted.

Leveraging MES and real-time process monitoring for Smarter Decision-Making

The data captured by MES during real-time process monitoring isn’t just about problem-solving. It provides a foundation for more informed and strategic decision-making across teams:

  • Engineering Teams: Gain insights into which parameters matter most for maintaining consistent quality, optimizing designs around repeatability.
  • Production Managers: Monitor multiple machines from anywhere on the factory floor to prioritize response efforts effectively.
  • Quality Teams: Build robust process qualification models to ensure products meet customer specifications with repeatable consistency.

Steps to Get Started

Manufacturers considering an MES to elevate quality assurance should take the five following steps to get started:

  1. Begin by Identifying Key Metrics – Define which parameters are tied to part quality (temperature, pressure, speed, etc.). Every operation and product will have its own critical factors.
  2. Integrate Sensors for Critical Monitoring – Ensure the right sensors are installed on machines to capture these metrics. Some machines may support built-in industrial internet of things (IIoT) communication protocols, such as OPC Universal Architecture (UA) or MTConnect.
  3. Establish Alerts and Thresholds – Work with quality and production teams to set tolerance levels, leveraging MES to flag deviations as early warnings.
  4. Analyze and Refine Continuously – Leverage MES historical data to refine processes over time, identifying trends and eliminating recurring issues.
  5. Drive Collaboration Across Teams – Encourage engineering, quality, and production teams to actively use MES data for continuous improvement.

Better Data, Better Products, Better Business

For small and midsize manufacturers, implementing an MES goes beyond enhancing quality controls to fundamentally change how factories operate. Real-time monitoring reduces scrap, cuts downtime, and boosts customer trust by ensuring consistent, superior quality. It’s not a luxury for manufacturers to consider; it’s an essential tool for staying competitive in today’s market.

Ask yourself—is it time to move from reactive fixes to proactive solutions? An MES could be the game-changer your operation needs.

DELMIAWorks