Digital quality management for the processing of plastics ensures the required high material quality. Through the digital integration of viscosity measuring devices, electronic scales and the connection of existing systems, we were able to digitally automate the incoming material inspection of plastics and permanently reduce costs.
Manual iterations as a bottleneck
Before our solution was implemented, viscosity tests were carried out manually in all test steps and by means of time-consuming manual documentation. Lists and spreadsheets do not protect against typing or manual transcription errors during manual recording or even accidental deletion of measurement logs.
An additional complication in the process is that the various test steps at the different measuring stations, from weighing and aggregate conversion to density and viscosity tests, each required the sample data to be recorded again at the different stations.
With a small team size, the number of possible samples automatically becomes the bottleneck of the quality inspection. In addition, the statistical monitoring of trends regarding materials, suppliers and variances was virtually impossible.
Automation boosts quality
By developing our solution with a direct connection to the measuring stations, we were not only able to digitally map the existing processes, but also introduce largely automated process and data analysis workflows, which gave the department the freedom to complete the existing workload not only without overtime, but also with a higher inspection density.
In this project, too, we were able to digitally strengthen the business through creativity, process understanding and comprehensive knowledge and skills in the area of data and application integration.
What else is digital quality management for plastics used for?
Digital quality management for plastics is used to monitor and ensure the quality of plastic products. This is achieved through the use of digital technologies and systems such as optical measurement technology and data analysis.
Specifically, digital quality assurance for plastics includes the following applications:
- 3D measurements: Optical metrology is used to perform three-dimensional measurements of plastic products. These measurements are used to check the shape and dimensions of the products and ensure that they meet the specifications.
- Surface inspection: Optical measurement technology is also used to check the surface quality of plastic products. This allows surface defects such as scratches, dents or impurities to be detected and rectified.
- Process monitoring: Digital quality assurance can also help to monitor quality during the manufacturing process of plastic products. Here, digital sensors are used to collect information about the process and production of plastics in real time. By analyzing this data, process deviations can be detected and corrected to ensure that products meet specifications.
- Data analysis: The recorded measurement data is evaluated and analyzed in real time. Deviations from the given specifications can also be detected automatically so that production can be adjusted accordingly.
Digital quality assurance for plastics achieves greater accuracy, reliability and efficiency in quality assurance. In addition, potential sources of error in the manufacturing process can be identified and eliminated at an early stage, which ultimately leads to better product quality and customer satisfaction.
