Build Quality
into Production
Identify quality issues earlier, reduce rework and make required checks part of the production process.
Why does manufacturing quality become difficult?
Manufacturing quality becomes difficult when quality control is treated as a separate process from production. Checks may be carried out separately, rely on operators remembering when they need to be completed, or only identify problems once work has already progressed.
Maintaining quality becomes easier when it is part of how production is carried out every day. Quality requirements are understood by the whole production team, checks happen at the right stage of the process and potential issues can be identified before they continue through production.
Longer Investigations
Checks that rely on memory can be missed or completed at the wrong stage of production.
Late Defect Detection
Quality issues can progress through production before being found.
Increased Rework
Problems found later require more time and effort to investigate, correct and rebuild.
Inconsistent Quality
Quality standards can vary between operators and shifts.
How to Improve Manufacturing Quality
Standardise the Production Process
Define a consistent production process with clear build instructions for each stage of work. This gives operators the same method to follow and creates a consistent foundation for maintaining production quality.
Build Quality Checks Into the Process
Review the production process to identify where mistakes or inconsistencies are most likely to affect quality. Build mandatory checks and sign-offs into these stages so critical requirements are verified as the work is completed.
Define What Happens When a Check Fails
Establish a clear process for responding when a quality check fails. Make sure the production team knows when work should stop, who needs to be informed and what needs to happen before production can continue. This helps contain quality issues and prevents affected work from progressing further.
Is Quality Built Into Your Production Process?
Use our free interactive Production Consistency Checklist to review how quality is controlled throughout production and identify areas where greater consistency could help prevent problems.
✓ Digital work instructions and operator sign-offs
✓ In-process quality checks
✓ Issue reporting and error-proofing
✓ Standardised training and production traceability
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Digital Production Systems
Manufacturing quality control software, such as a Manufacturing Execution System (MES), can bring quality control into the production process by connecting production activities with the checks required at each stage. Operators can be prompted to complete checks as work progresses, with results recorded as part of the production record.
This makes it easier to maintain quality processes across production and identify issues earlier. Checks, results and production information are captured as work happens, reducing the manual effort needed to manage separate quality records.
Screenshot of Tascus
Manufacturing Quality in Practice
See how manufacturers have improved production quality using Tascus.
Off-Highway Vehicle Components
Reducing End-of-Line Rework by Over 50%
A global manufacturer of control systems for off-highway vehicles implemented Tascus to embed production control and quality checks directly into a new manufacturing cell.
Production activities are now verified throughout the manufacturing process, helping identify potential issues before final inspection and reducing end-of-line rework by over 50%.
Key outcomes:
- Over 50% reduction in end-of-line rework
- Earlier identification of quality issues
- Quality checks embedded into production
Aerospace Manufacturing
One Complete Production Record
A leading aerospace manufacturer implemented Tascus to bring production records and quality requirements into one controlled manufacturing workflow.
Quality checks and production confirmations are now completed as part of the production process, supporting greater accountability and more consistent processes across operators, shifts and locations.
Key outcomes:
- Embedded quality checks
- Greater production accountability
- More consistent production processes
Manufacturing Quality with Tascus
Tascus is a Manufacturing Execution System (MES) developed by Metis Automation that brings quality control directly into the production process. Operators are guided through each stage of work, with required quality checks completed and recorded at the appropriate point in production.
Checks can be completed by operators or verified using connected equipment such as barcode scanners, smart tools, sensors, cameras and automated testing equipment. This helps identify potential issues earlier and creates a clear record of the checks and production activities completed for each product.
This gives manufacturers greater control over production quality, helping maintain consistent processes and reduce the risk of problems progressing through production.
Related Resources
Quality Control in Manufacturing Explained
Learn why manufacturing quality control breaks down and how to build quality into the production process.
Reducing Variation in Your Manufacturing Process
Learn what causes production variation and how to create more consistent processes across operators and shifts.
Production Consistency Checklist
Review your production process to identify missed checks, inconsistent standards and opportunities to improve quality.
Quality as a Mindset with Suresh Babu
Download a free manufacturing traveller template to standardise production records and improve traceability.
Production Workflow Review
Every production is unique. Our Production Workflow Review helps identify where quality checks are missed, where issues are being found too late and opportunities to improve quality control throughout production.
