Post on 28-Jan-2021
1
Quickly and easily gain insight into your production processes
• Construct personalized dashboards to monitor key indicators of manufacturing quality and performance
• Generate detailed reports in seconds instead of hours
• Manage your production line proactively, instead of reactively
• Accurately monitor production line performance, driving continuous process improvement
• Maximize yields by quickly identifying the cause of bottlenecks in manufacturing processes
Develop a deeper understanding of manufacturing processes through analysis of stored process signatures
• Quickly compare signatures from 1000’s of parts to identify features that can be correlated to product quality
• Re-analyze stored signatures to quickly optimize spec limits and test parameters
• Identify new failure mechanisms and develop new feature checks based on re-analysis of historical waveforms
• Accelerate process development, new product introduction, and line launch
• Analyze waveforms, review trends, and correlate across stations to quickly identify root causes of defects without the need for expensive and time-consuming destructive tests
Maintain 100% traceability through detailed records of end-to-end manufacturing data
• Collect and store the complete test record for every part – including process signatures—from a broad range of manufacturing hardware, including third-party tools, testers and PLCs
• Provide proof of compliance and retain detailed birth history records for regulatory requirements
Minimize the impact of quality spills and reduce warranty costs
• Quickly identify other affected parts without the need for tearing down or re-testing parts – based solely on re-analysis of stored signatures
• Confine recalls to only the defective parts
QualityWorX is the Quality Operating System that automates the collection, storage, archiving, retrieval, analysis and reporting of test
and assembly data for discrete manufacturing. It delivers unparalleled insight into critical manufacturing processes, providing the
competitive edge demanded by today’s manufacturers. From the plant floor, to the engineering labs, to management offices around
the globe, QualityWorX delivers the visibility manufacturers need to meet their production goals of improving both quality and yield
while reducing costs.
FEATURES & BENEFITS
2
FUNCTIONAL OVERVIEW
Remote Office
EthernetSwitch
WebServer
MES or ERP
PlantFloor PC
sigPOD
sigPOD
PLC
Third ParyTester
sigPODGateway
EthernetSwitch
Remote Office
Reporting Tools
Central Database
Engineering Workstation Analyst
QualityWorX is a suite of software tools that automates the collection, storage, analysis, and reporting of manufacturing data. It
combines the flexibility and speed of a SQL database, the power of advanced analytics, and the ease and accessibility of web-based
reporting. All types of production data, including assembly, test, and repair operations, are collected from a wide range of plant
floor systems for storage within the QualityWorX database. Reporting and analysis tools access the database across local and wide
area networks, providing critical insight into the manufacturing processes and production line performance to all levels within the
manufacturing organization.
3
COMPONENTS OF QUALITYWORX
SUPPORTED DATA CONNECTORSSigPOD Automatic connection to sigPOD units
OPC Connects OPC server to device (e.g. PLC)
Rundown Tools
Atlas-Copco PowerMACS, PowerFocus
Bosch Rexroth Tightening Systems
Data Connectors
XML QualityWorX XML format
Serial Multiple ports (real + virtual), handshaking supported: OPC, DI/DO
FTP Client sends data to FTP server, XML file format
PLC Data transmission using OPC server (e.g. Kepware) or fieldbus via sigPOD or Gateway – PROFINET, EtherNet/IP, Modbus TCP,
PROFIBUS, DeviceNet
Insertion API Proprietary API allows 3rd party software applications to push data directly into QualityWorX
SQL DATABASEAt the core of every QualityWorX installation is a SQL database
built on Microsoft SQL Server technology. Architected to
efficiently store and organize all of your production data,
including process signatures, features, spec limits, part-specific
parameters, and defect and repair data. Management tools facilitate the configuration of the database structure and the regular,
automated archiving of stored data.
The database is designed to grow with your testing and manufacturing needs. Multiple QualityWorX Data Servers can run at the same
time. Automated utilities gather old history data in secure archives, without any interruption in production. This ensures speedy access to
the latest production data while still allowing for full analysis of all current and archived data.
INTEGRATE SEAMLESSLY WITH PLANT NETWORKSAdd QualityWorX to your plant network and quickly begin collecting and analyzing data from the entire family of sigPOD test stations.
Proprietary connections can be enabled to pull data from fastening and rundown tools including Atlas Copco, Bosch, and others.
Open standards such as XML and OPC ensure that 3rd party devices are also able to leverage the storage and analysis power of the
QualityWorX suite.
During production, new models and parts can be configured on the fly, and test stations can be added or deactivated in QualityWorX
without any production downtime.
4
The Web Reporter is the standard reporting interface for QualityWorX, and a site license is provided with every database installation. The
Web Reporter combines a simple, but powerful web-based interface with a comprehensive library of standard reports to enable all levels
within the manufacturing organization to quickly retrieve, analyze and summarize production data.
ACCESSIBLE TO ANYONE, ANYWHERE • Web-based application provides complete access to quality data from any computer
with a network connection
• Simple, intuitive interface makes it accessible to all levels within the organization,
from technician to manager
• No local software to install, all you need is your web browser – simply install the
application on your web server, configure and go!
COMPREHENSIVE LIBRARY OF POWERFUL REPORTS• Quickly and accurately calculate First Time Yield, and identify
top failure categories
• Generate detailed summaries of product quality, performance
and yield using one of eight powerful, configurable reports
• Precisely define desired dataset using flexible, powerful query
builder
• Export any report to PDF or Microsoft Excel native format, or
generate printer friendly versions for printing directly from
your browser
• Click on a serial number in any report to drill into its detailed
birth history record
• Report tables feature drill-downs or collapsible tables to
expose as much, or as little detail as desired
STANDARD REPORTS1. Part History
2. First Time Yield
3. Summary Report
4. Trend Browser
1 2
3
4
Create a Report in 4 Steps1. Enter query parameters.
2. Click button to select report.
3. Fill in report options.
4. Launch report.
5. Failure Report
6. Failure Pareto
7. Repair Traffic
8. Defect Pareto
5
First Time Yield
Trend Browser
Summary Report
STANDARD REPORTS IN WEB REPORTER
Part History
Intuitive tree-based navigation of birth history data enables detailed investigation of
pass/fail results, waveform characteristics and feature checks on a single serial number.
First Time Yield
Calculate First Time Yield (FTY) by station or Rolled Throughput Yield (RTY) across
multiple stations.
• Toggle chart between FTY vs. station, and RTY vs. time, where RTY is calculated over
a period of a day, week, or month, as selected by the user.
• First Time Yield is the number of unique parts without any failures (at that station),
divided by the total number of unique parts through the same station.
• Rolled Throughput Yield is the product of the individual station FTY values.
Summary Report
Generate a detailed summary table of operation yields, or click on an operation to bring
up a detailed table of feature statistics. User selects from a list of 13 statistical parameters
that can be incorporated in the feature table, as well as embedded charts that provide
quick, at-a-glance displays of feature trends.
Trend Browser
Drill down to individual operations or features and display trend chart vs. serial number
or date-time stamp. Toggle between detailed serial number list, and yield and statistical
summary.
Failure Pareto
Quickly generate a Pareto chart of the top 10 failures. Drill down to a list of affected
serial numbers, then link to individual part history report to quickly isolate and identify
production issues.
Failure Report
Review detailed listing of failed serial numbers with breakdown of individual failures by
station and operation.
Defect Pareto
Create Pareto chart of top 10 defects, categorized by defect or repair details. Drill-downs
and links to individual serial numbers assist in rapid identification of primary sources of
defects (only available if Sciemetric Repair Bay Manager installed on production line).
Repair Traffic
Detailed list of all serial numbers that have been repaired, specifying both the defects and
the repairs (only available if Sciemetric Repair Bay Manager installed on production line)
6
The QualityWorX Dashboard provides a unified reporting environment
that supports three distinct levels of reporting, each providing
progressively higher levels of detail. First, the Dashboard tab provides
high level, at-a-glance summaries of key manufacturing metrics.
Clicking on a dashboard report brings up the corresponding Report
page, which combines tables and charts to provide the next level of
detail. The Reports and Part History can also be accessed by selecting the
corresponding tab, then applying the desired the database filters and
report options. Report configurations can be saved and then launched
directly from the Report Manager, allowing you to quickly generate commonly used reports without having to re-enter query parameters.
The layout of the Dashboard web page is shown in the figure above. Navigation between the three reporting levels is performed by selecting
the appropriate tab at the top of the main panel. Other functions, such as the Report Manager or Preferences, are accessed from the toolbar
anchored to the left of the main panel. File management buttons are grouped in a second toolbar at the bottom of the main panel.
The Dashboard offers three categories of reports: Dashboards, Standard Reports, and Part History.
The following chart types are supported in the Dashboard library:
Needle Gauge
CHART TYPE CHART FEATURES CHART OPTIONS SIZING OPTIONS
Pie Chart
Line Chart
Bar Chart
• Numerical value prominently displayed at bottom of gauge
• Red, Yellow, Green zones for rapid visualization
• Text labels indicate numerical breakdowns
• Shading (select reports) provides visual emphasis of upward or downward trends
• Below target values highlighted in red – above target in green
• Limit the number of bars displayed to prevent overcrowded reports
• Sort columns in ascending or descending order
• Small, medium, large diameter• Font size: small, medium, large
• Small, medium, large diameter• Font size: 8, 10, 12, 14, 16,
18, 20 point
• Small, medium and large size• Aspect ratio: 1, 1.5 and 2• Font size: 8, 10, 12, 14, 16, 18, 20
point
• Small, medium and large size• Aspect ratio: 1, 1.5 and 2• Font size: 8, 10, 12, 14, 16, 18, 20
point
• Upper/Lower bound of gauge range• Minimum (upper bound of Red range)• Target (upper bound of yellow range)
• Target value – displayed as solid green line
• Target value – displayed as solid green line
7
DASHBOARDSThe Dashboard tab provides a user-configurable environment for creating concise, at-a-glance summaries of key performance indicators.
Configuration options include:
• Create sub-tabs to organize your reports. Re-position reports within the tab simply by dragging and dropping
• Dashboard configurations are saved automatically with every change. Export configuration files to your local computer and share with
other users
• Configure sizes of charts, and choose font sizes to suit your display
• Each report offers a variety of configuration options that enable you to tailor each instance to address a specific metric
In addition, the Dashboard offers the following powerful features:
• Most Dashboard reports feature click-throughs that automatically bring up detailed reports on the same dataset, allowing the user to
drill down from high level summary to low level detail in just a few clicks. For example:
- Click on a bar in an FTY Trend to generate a Failure Pareto report for the dataset associated with the specific FTY bar, then drill down to a
serial number and open its part history report to review its waveforms.
- Open a part count report that features dynamically adjustable binning by clicking on a Part Count gauge or trend chart.
• “Marquee view” – this option allows the administrator to configure a live dashboard that is automatically updated based on a
configurable timer. Designed for use as a public display board, whether on the plant floor or in the office, the Marquee view features a
narrower top banner and removes the toolbar to maximize the available display area. Accessible only with an Administrator login.
The current library of dashboard reports includes the following report definitions:
Failure Pareto
Feature Trend
First Time Yield Gauge
First Time Yield Trend
Parts Count Trend
Parts Count Gauge
Operation Gauge
REPORT DESCRIPTION CHART TYPE CHART FEATURES AND OPTION
• Bar chart• Pie chart• Line chart
• Needle gauge
• Line chart (shaded)
• Bar chart• Line chart• Bar chart
• Line chart (shaded)
• Bar chart
• Pie chart
Display top failures by station or operation
Drill down to a specific feature on any station, operation, or waveform, and plot vs. time or serial number
Display FTY across a selection of sections and stations
Trend FTY vs. time or compare FTY by model, section, station or part parameter
Trend parts count over time or compare by model, section, station, or part parameter. Use the op count filter (first, last, >, ,
8
ANALYSIS GRID
Flexible spreadsheet-like table allows engineers to create custom analysis and charts. Add columns with mathematical formulas, sort, apply filters
or aggregate data (sum, average, minimum, maximum). Export your charts to a Dashboard panel with a few clicks.
REPORTS
The Dashboard includes all of the standard reports offered in the Web Reporter,
including the Part History report. While maintaining the same general interface and
layout, the Dashboard adds a number of powerful and convenient features:
• The user can save and load report configurations to quickly generate
frequently used reports.
• Configuration files can be exported or imported to/from the desktop so that
they can be shared with colleagues.
• Account-specific preferences allow the user to choose default settings for
each report type.
• Click-throughs on select reports enable rapid drill-downs
In addition, the new Analysis Grid custom analysis tool has been added to complement the original eight reports.
Operation Trend
SPC Trend Chart
Feature Comparison
Feature Gauge
• Line Chart
• Line Chart• Bar Chart
• Bar chart
• Needle gauge
Plot operation result vs. time to reveal if there are any unusual trends in the pass/fail results
Drill down to a feature and trend Avg, Min, Max, Sum or Std Dev vs. time, grouping by time-date or by number of records (eg: every 10 data points), or plot vs. model or part
Compare Avg, Min, Max, Sum or Std Dev between multiple features, across sections, stations, operations and waveforms
Track a feature value in a gauge, selecting from Avg, Min, Max, Sum or Std Dev.
• Aggregate by Avg, Min, Max, Sum, Std Dev, • Bin time by shift, hour, day, or week• If the same feature label appears in multiple
stations, compare sections, stations
• Limit number of bins and sort in ascending or descending order
• Aggregate by Avg, Min, Max, Sum, Std Dev
REPORT DESCRIPTION CHART TYPE CHART FEATURES AND OPTION
9
PRODUCTIVITY TOOLS
The Dashboard features a set of productivity tools that help accelerate report generation through personalization,
file management and information displays. In addition, administrators can tailor access to specific functionality
through a simple user rights management interface.
REPORT MANAGER
The Report Manager provides a convenient utility for managing stored definition files created in the Reports or Dashboard tabs:
• load a stored report configuration into the “Reports” tab, ready to be edited
and launched
• delete or rename report files
• Import or export files from the server directory to a local directory to enable
you to share files with other users
• launch reports directly from the Report Manager file list
PREFERENCES
Each user can set their own personal preferences to help facilitate rapid report
generation. Available preferences include default settings for all of the Reports and
many of the Dashboards.
ADMIN TOOLS
The Admin Tools tab contains configuration and administration settings that are
only available to logins that have administrator privileges. Within this section,
there are three divisions, each organized into its own tab:
1. Connection Manager: allows the administrator to edit or delete existing
production line definitions, or configure new ones
2. Rights Management: contains User Rights Management settings, where access
to reports, features and tools can be enabled or disabled based on user groups
3. Admin Password: Provides management of the Dashboard administrator’s password, which is used to gain access to the Admin Tools
from the login prompt
10
For advanced data analysis, the Engineering Workstation features a powerful mathematical
processing engine that can simultaneously analyze thousands of waveforms, rapidly
simulate a broad range of test scenarios using historical data, or identify defects using
line-wide trends and correlations. These advanced capabilities are combined with a suite
of standard reports to provide the ultimate in data analysis and reporting environments. Engineering Workstation is ideally suited
for Manufacturing and Quality Engineers who are tasked with developing and implementing new production processes, maximizing
production yields, optimizing throughput, and identifying root causes.
DATA ANALYSIS The Data Analysis function is a sequence editor that applies a series of functional steps to a dataset. A dataset consists of process
signatures and/or scalar data points for a specified subset of parts. Feature values can be extracted from the waveform data
by applying sequences of signal processing steps and signature analysis algorithms. Limits can be applied to feature values,
and optimized to ensure accurate separation of good and bad parts. This allows areas of interest to be isolated, compared and
manipulated, leading to the identification of manufacturing anomalies, which can then be eliminated by fine tuning the appropriate
process control limits.
Waveform Processing Functions
ClipperConcatenateDerivativeExtract WaveformFFTHigh, Low or BandpassIntegralKernelLinear FilterMax TrackMin Track
Waveform Feature Types
AreaCuspEnvelope WindowGet Y at XKneeKurtosisMaximumMeanMedianMinimumNumber of Points
Sequence Editor Functions
Data and Waveform Calculate Apply Signature Analysis function Apply Process Data functionLimit Check Conditionals and Loops: If, Else, While
Moving Window RMSNotch FilterPop Noise FilterRemove DCSmootherSynchronous Filters
Peak to PeakPower SumRise/Fall TimeRMSSkewSlopeStandard DeviationThreshold CountThreshold CrossingVariance
11
STANDARD REPORTS IN ENGINEERING WORKSTATION ANALYSTIn addition to the powerful analysis tools described above, the Engineering Workstation also comes
with seven standard reports. The majority are shared with the Web Reporter and are described in
detail in the Web Reporter section. The Real-Time Status report is unique to Engineering Workstation,
and the Trend Browser offers a number of additional features not present in the Web Reporter
or Dashboard.
Trend Browser
A more powerful version of the Trend Browser in the Web Reporter and Dashboard, it offers the
following additional features:
• Overlay multiple waveforms on common axes to spot variations over multiple test stations and parts
• Highlight an individual trace by clicking on the serial number in the legend
• Overlay control limit waveforms (e.g. 3-sigma envelope)
• Zoom / pan / isolate and highlight data points
• Plot feature data as a histogram / R-chart / X-Bar / line chart
• Identify serial number by clicking on a data point on the graph
Standard Reports
1. Part History
2. Trend Browser
3. Failure Report
4. Failure Pareto
5. Repair Traffic
6. Defect Pareto
7. Real-Time Status
2
2
34
1
This example shows process signatures from 1000 parts captured at the same test station. 4 types of signature groupings can be easily seen.
1. Compliant: Well-behaved signatures, tightly grouped and exhibiting expected characteristics.
2. Not compliant: These signatures clearly deviate from expected behaviour. Easily detected by most test systems.
3. Not compliant: In this case these are true failures that exhibit some of the desired behaviors, but still deviate from the norm. Easy to detect with process signature technology, but more difficult to catch with classical systems.
4. Almost compliant but still failures: Subtle deviations from “normal behaviour” that would pass most tests and are only clearly visible in process signatures analyzed by QualityWorX.
Real Time Status
The Real Time Status is automatically updated at a user-controllable rate to provide real-time production trends. The Real Time Status
report takes a snapshot of information in the QualityWorX database according to user-specified criteria.
• View real-time data on part pass/fail, timestamp
• Select a live part to see its part history
12
OPTIONAL COMPONENTS
DATABASE MANAGEMENT TOOLS
ERP BRIDGE Add the MES / ERP Bridge option to the QualityWorX network to
provide:
• Configurable, secure access to scalar data contained within the
QualityWorX Data Server
• Flat table structure that dramatically simplifies access to database
fields
• Exposure of live part information such as status, test results and
build codes
• Data transfer simplified using auto store and removal functions
REPAIR BAY MANAGER Add the Repair Bay Manager module to the QualityWorX network
to provide defect and repair management:
• Guides operators through repair process with complete access to part
history record
• Suggested repair function (based on defect type)
• Stores all defect and repair information in QualityWorX database as
part of birth history record, including location, component, defect
type and repair type
• Provides both manual and automatic interface to the production
line for entry and release from repair station
• Runs as a separate application on a sigPOD 1010 Data Node or any
PC running Windows XP Pro, with a connection to the QualityWorX
database
The database management tools are included with every database license. These tools are typically used by the database administrators
to configure the production lines within the database, and manage the archiving of data from active databases.
ARCHIVE TOOL The Archive Manager is used to manage the data stored within the database, by allowing the database administrator to copy, move
or delete records. Archive jobs can be created, saved and executed from the Archive Manager interface, or can be scheduled to run at
regular intervals using the Windows Scheduler utility.
CONFIGURATION TOOL The Configuration Tool is a utility that allows the system administrator to configure production lines in the database. This includes
defining all the part types, sections, and stations, as well as the relative order of the stations in the line. It is also used to deactivate stations
or serial numbers. All production line database users and passwords are managed with the Configuration Tool.
13
PRODUCT CONFIGURATIONS
DATABASE CONFIGURATIONS
• QualityWorX® Base Five (5) connection database license for installation on a
customer provided Microsoft® SQL Server 2005 or 2008 R2
running on a 32 or 64-bit MS Windows® OS. Includes one
(1) unidirectional connector and Web Reporter site license.
• QualityWorX® Enterprise Unlimited1 connection database license for installation on
a customer provided Microsoft® SQL Server 2005 or 2008
running on a 32 or 64-bit MS Windows® OS. Includes Web
Reporter site license.
• QualityWorX® Enterprise Secondary2 Unlimited1 connection database license for installation
on a customer provided Microsoft® SQL Server 2005
running on a 32-bit MS Windows® OS. Licensed for use on
a Primary database feeder line.
• Engineering Workstation Analyst Single License One (1) concurrent license to connect to a QualityWorX
Database and all Secondary databases on same Product Line.
• Engineering Workstation Analyst Site License Unlimited concurrent licenses to connect to a
QualityWorX Database and all Secondary databases on
same Product Line.
• QualityWorX® Enterprise Bundle Unlimited1 connection database license for installation on
a customer provided server Microsoft® SQL Server 2005
or 2008 R2 running on a 32 or 64-bit MS Windows® OS.
Includes Dashboard site license.
• QualityWorX® Dashboard Site License Advanced web-based reporting tool for QualityWorX.
License allows for unlimited client connections and an
unlimited number of separate QualityWorX database
connections. Provides a single instance of the web server
application only. Maintenance, installation and training
charged separately.
1 Total number of connections limited by server capacity and configuration.
2 A secondary database is required for each feeder line associated with the primary assembly line (e.g., head assembly, head machining, block machining etc.). One secondary database can support multiple, identical lines (e.g. three head assembly).
HARDWARE PACKAGE
• Model 1010 SigPOD Data Node Platform
• Runs data connector applications to connect 3rd party
hardware to QualityWorX server
• Compact form factor and Industrialized packaging for flexible
placement on the plant floor
• Supports up to 10 connections to a QualityWorX server
• Includes Windows XP Pro, CPU, DVD-R/W drive
14
www.sciemetric.cominquiries@sciemetric.com1-877-931-9200© 2013 Sciemetric Instruments, Inc. All brand and product names are trademarks or registered trademarks of their respective companies. Products and specifications subject to change without notice.
Rev 5, May 2013
Min 2.4 GHz Pentium dual-core processor or equivalentXeon 3.0 GHz processor recommended
4 GB min
80 GB free hard disk space min, not including size of customer data, which depends on application.Database drive should be RAID 1 configured for data backup.Note that database performance is dependent on drive seek/access times.
CD-ROM, Backup system (DVD/DVD RAM/Tape): Tape backup is highly recommended
SVGA (800x600)
Microsoft Windows Server 2003 or Microsoft Windows Server 2008 – 64 bit
Microsoft SQL 2005 Standard Edition, or SQL 2008
Ethernet 100 Base T connection
QualityWorX Data ServerSQL database and associated management tools
QualityWorX Web Reporter ServerOR Dashboard Server
QualityWorX Engineering Workstation Archive ToolConfig ToolAdvanced desktop analysis and reporting software
Min 1 GHz Pentium dual-core processor or equivalentXeon 3.0 GHz processor recommended
4 GB min
1 GB of free hard disk space min
CD-ROM
SVGA (800x600)
Microsoft Windows Server 2003 or Microsoft Windows Server 2008 – 64 bit(Recommended)
Microsoft Internet Information Server (IIS) Microsoft .NET Framework 2.0 (or later)
Ethernet 100 Base T connection
Pentium® 4 (or equivalent), 1.8 GHz or higher
1 GB min
2 GB of free hard disk space min
CD-ROM
XGA (1024x768)
Microsoft Windows XP Pro, min SP2
–
Ethernet 100 Base T connection
PROCESSOR
MEMORY
HARD DRIVE
REMOVABLE DRIVE
DISPLAY
OPERATING SYSTEM
ADDITIONAL SOFTWARE
CONNECTIVITY
HARDWARE INSTALLATION REQUIREMENTS
Web-based reporting application