In order to guarantee the quality and compliance of the products (such as raw materials, semi-finished and finished goods) it is necessary to execute in a precise and punctual manner a series of qualitative tests, both at the goods receipt and during the execution of the process, through easy procedures to be carried out in real time. Quality controls can be executed by operators or generated automatically by machines, according to organized and planned events (quantity reached, working times and tools calibration…).
OPERA MES contains three key concepts in the Quality Control area: Product Compliance, Product Genealogy and Process Control.
QUALITY TESTS ACQUISITION AND MANAGEMENT (Product compliance)
OPERA guarantees the product conformity through the managing and acquisition of the quality checks in the production. The system allows the definition of quality tests on raw materials, semi-finished and finished goods; electronic tests dispatching and real time data acquisition and monitoring for an immediate reaction to possible problems. An accurate analysis of the results (lots status, tests results, tools used, operators involved, non-compliance reasons recorded, etc.) enables the determination of the main reasons affecting products defects and the identification of the best corrective actions to guarantee the quality of both products and manufacturing processes. OPERA MES manages both attribute tests (visual inspection) and instrumental tests (values measurement). The main functionalities are:
- Quality tests definition on raw materials, semi-finished and finished goods
- Dispatching and execution of the quality tests
- Real time quality checks data acquisition (manually and/or automatically)
- Quality data real time monitoring
- Quality data report and historical analysis
PROCESS CONTROL (SPC)
With process control, for each production order/lot it is possible to set a constant control of the productive process values. Through a direct connection with devices, control systems and/or measurement tools, the system collects and records process values, highlighting the process variables, with the aim of promptly and quickly eliminating the 'special causes' that mostly affect the quality of the product, then trying to take corrective actions to remove them one by one. For this purpose, OPERA uses control charts, allowing the monitoring of the chart values and the immediate identification in case the process is out of control, as well as trigging "errors" and events (plant downtime, quality control request, maintenance request, etc.), in order to promptly solve the process criticalities detected.
LOTS TRACKING AND TRACING (Product Genealogy)
Tracking and tracing are procedures used by companies to recreate the genealogy of a product, recording every single component of the product, to guarantee its quality, while managing any non-compliance situations. Tracking makes it possible to track the lots of materials used in the production of the finished product, from the origin of the product to its distribution. Traceability, on the other hand, is the reverse path and allows, given a finished product, to trace the data of the compound detected during the production phases, to allow the recall of the product. OPERA allows to record, during the progress of processing, millions of records that report every moment of "life" of the product. The main features are:
- Monitoring of raw (or semi-finished) materials quantities consumed
- Collecting information related to the quantities produced in production
- Generating new lots to identify the material produced
- Monitoring of the components stock levels on the machine