Most Manufacturing Execution Systems ( MES ) encompass a wide range of quality control areas. More specifically, this includes inspection and verification steps throughout the process, statistical process control (SPC) procedures, out-of-control condition alarms, and the comprehensive handling of discrepancies discovered during production, as well as managing defect control and corrective actions to prevent recurrence.
When building complex products, labor and parts costs can escalate rapidly. Therefore, reworking products is often the preferred option for complete disposal. Rework, repair, and deviation handling procedures are best managed by an MES (Management System), ensuring their documentation is part of the product history and their dissemination so that deviations can be reviewed and approved by the appropriate personnel.
Production inspection planning and execution
Inspection, testing, and verification requirements are typically handled by inspection plans. Modern manufacturing operations have shifted inspection efforts across the entire project lifecycle, rather than a single final inspection. Furthermore, there is more random sampling inspection rather than a 100% project review. This, of course, makes tracking and documentation more challenging and critical than ever before. People in production also tend to take on more ownership of product quality. MES (Manufacturing Execution System) plays a role by helping to integrate quality measures into the production process. When set up correctly, MES can require process checks using signatures before proceeding to the next step in the production process.
MES can also recall the tools or instruments to be used and track this information, providing important documentation when needed for future problem measurement.
If measurements are required for Statistical Process Control (SPC) monitoring, the MES can collect measurements from different work orders and display them on SPC charts during production. This is where the MES's quality enforcement capabilities truly come into play, as it can issue alerts for non-compliant conditions and use rules to alert for SPC out-of-control conditions.
AS9100 is an aerospace standard based on the International Organization for Standardization (ISO) 9001 quality system requirements, designed to meet the quality requirements of the Department of Defense, NASA, and the Federal Aviation Administration. It mandates First Article Inspection (FAI) or Product Process Validation (PPV) for the aerospace industry. These inspections are triggered by major product or process changes and verify that "the manufacturing process still produces the expected results according to engineering specifications."
Production data for each product unit or batch, along with corresponding inspection, testing, and final inspection results, are stored in the MES system. This data can be easily accessed and delivered with the product if requested by the customer. The MES system can also report delays caused by inspections awaiting completion.
Product Configuration Verification
Every manufacturer wants to deliver products ordered. This is a challenge for manufacturers that design to order because many changes can occur throughout the production process. The manufacturing system needs to ensure that the final product conforms to engineering specifications. Equipment history records (DHRs or as-built reports) can be helpful, as they contain a list of Engineering Change Notices (ENCs) for each product. Furthermore, deviations should always be reconciled and approved according to the design configuration, as needed.
Non-conformity and Defect Management
In addition to calculating defects, scrapped materials, and production output, MES must also track the handling and management of non-conforming results. It must include deviation approval and the execution of planned manufacturing processes.
"Defect control measures may include corrective action requests sent to suppliers, evaluation orders for products and materials in inventory, alerts for production orders that may be affected, and product recalls (or warnings) sent to customers."
If inspections reveal non-compliance with engineering specifications, this should be documented. Once routed through the disposal and approval process, the product or component will be categorized as: scrapped, returned to the supplier, reworked, repaired, or used as is. With an integrated production and quality management system, mechanics rarely skip rework or repair instructions.
Different types of discrepancies and severity levels require different handling and approval routes. Some may only require approval from the quality assurance team, while others may require approval from the product engineering department.
Categorizing defects and nonconformities by cause type and responsible department facilitates reporting, and once the data is analyzed, areas for improvement can be identified. MES can initiate corrective actions to "address recurring issues recorded in variances." These actions should be linked to variances to track improvements in design, processes, and suppliers. Efficiency MES solutions will provide multi-level reporting capabilities, enabling a leaner and more efficient production environment, reducing losses and increasing productivity. The MES system is the core of an enterprise's information system and a crucial component of intelligent manufacturing construction.
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