Technical Features White Paper
To produce materials that meet demanding specifications for quality, a systematic approach must be adopted
for the measurement and tracking of quality test results. But, implementing a quality program presents the
organization with many process, technical, and human capital challenges.
Ei3 Corporation provides the converting industry with a unique and powerful way to implement a quality
control program. Quality management, can manage, input, track, and report the quality results of your
products. If you want to increase yield take a look at the features of Quality Management.
A powerful quality system
Quality management provides tools to help implement a
Quality Management is designed for converting compa-
product quality program. Quality managers, six-sigma black
nies that want to implement quality management best
belts, machine operators and production personnel are pro-
practices, six-sigma or SPC, and puts workflows into
vided with web pages that guide their activities. Data is
action that enable them to reach higher yield and produc-
acquired, displayed, reported and archived to drive aspects
of a quality program.
A Critical to Quality, or CTQ, parameter defines the
manufactured characteristics a customer expects of a
Easy to Configure, Easy to Use
product. Therefore it is important that the results of tests
for the CTQ parameters are available for analysis and
Administrators define quality tests and limits for CTQs.
reporting within the manufacturing organization.
Then, machine operators are provided with clear web page
Quality management provides the ability to manage, in-
forms to input their test results. These results are stored
put, track and report on CTQ parameters. Further, ma-
and displayed in real-time on a quality dashboard. RTQ
chine parameters that are related to quality, RTQs, are
machine parameters are monitored to prevent quality
monitored and correlated to the CTQs enabling benefits
problems. Reports are generated for management, and the
of advanced quality management and SPC.
archived results serve as quality certificates for customers.
Quality Management works by monitoring the
machine parameters that affect quality, and
alerts operators to achieve better CTQ results.
Flexible Framework for Quality Configuration and Data Input
Convenient On-line Configuration
Quality management has a flexible framework that
manages testing workflows and categorizes data. It
works with most established quality programs by put-
ting existing methods and workflows on-line. During
configuration, the quality administrator uses Quality
Management to create a data form for each product
specification and operation. The form groups the test
methods, frequencies, formulae and documents to be
displayed to machine operators during the production
run. Once the configuration is complete the dashboard
updates to reflect changes made in the forms. For
example, new quality spec limits for tests are posted
immediately to maximize product yield.
Operator Test Data Entry Forms
During a production run the quality management dashboard
prompts machine operators or quality technicians through the
process of testing materials. The tests and specification limits are
sourced from the configured data forms. From the dashboard, a
window appears for each unit to be tested and guides the operator
step-by-step through a clearly defined workflow.
Many test types are accommodated, including: Pass/fail, letter
grade, numeric input, multiple numbers, and mathematical
equations. Also interfaces are available to connect directly to test
devices to reduce the change for data entry errors. Operators can
enter notes that become part of the production run quality record.
Tracking the Work Order
Quality is tracked by work order to provide powerful reporting and analy-
sis capabilities. Information sourced from multiple converting operations
such as printing, laminating slitting, folding and gluing is combined on
the quality report to provide a complete record for each work order
A Work Order is created for each set of material to be produced and is
linked to a customer and a product specification. Optionally, the work
order can be assigned to a manufacturing location and given a design.
Quality management can work in concert with existing QC programs and
the data can be directly linked to business ERP systems to create even
Valuable Machine Information
Real-time SPC for the converting plant
Quality management brings real-time SPC to the converting plant and puts established best practices to work. Information is dis-
played in a practical and clear manner that empowers operators to react quickly to changing conditions. Important Related-To-
Quality, or RTQ, parameters are monitored using SPC to alert on potential problems. Quality management uses “run-rules” to
display the status of the RTQ parameters to focus operator attention and filter out nuisance alarms. For the most critical parame-
ters a run-rule status box is provided on the quality dashboard to provide constant visibility.
RTQ Status Box
Important machine parameters Name The machine measured parameter, red in alarm
are monitored using the RTQ
status box. SPC Run-rules are Status Color blocks indicate data points and run-rules
used to show when a parameter
goes out of control. Up to ten CTQ The CTQ affected by the RTQ parameter
critical RTQ status boxes can be
Time Hours and minutes the parameter has been in
displayed on the dashboard si-
one of the run rule alarm states, and # of alarms
Clicking on the title of the RTS status box brings up a six-sigma control chart showing the last 60 sam-
pled points and their control zone as specified for the CTQ. (+/- one sigma per color band)
ZONE Control Charts
A Real-time control charts display
B monitored machine parameters
that may affect product quality.
Six-sigma zones are displayed in
C color to help determine if the
B parameter might cause quality
This technique provides users with
a powerful pro-active quality tool.
Run rules are a proven and reliable method for spotting a parameter that is out of control and
are used by Quality Management to alert machine operators of potential problems.
Rule Name Rule Description
Eight (8) Eight successive points are on the same side of the mean
Four-of-Five (4/5) Four out of Five successive points fall in Zone B or beyond POWERED BY
Two-of-Three (2/3) Two out of three successive points fall in Zone A or beyond
One (1) A single point falls outside the 3 Sigma limit, i.e. beyond Zone A
RTQ Rule Engine Results In View QUALITY MANAGEMENT DASHBOARD Overview
RTQ, Related To Quality, alarms are logged for the current During production there are many tasks competing for the machine operator’s attention. Machine and Production information is displayed
work order and guides operators to take corrective action. Because yield is important, operators must be made aware of quality issues but ‘information
overload’ from unnecessary data can impair productivity. The ergonomic single-screen de-
sign of the quality management dashboard is the result of a thorough analysis of operator re- Machine Speed Shows the actual, setpoint and recipe target speed
Time Stamp The time that the RTQ alarm occurred
quirements. It provides a real-time overview of production quality and highlights results to Production Order Information about the actual order currently being produced
RTQ Name The RTQ parameter that went out of control empower operators early for prompt reaction to remedy potential problems.
Violation The run rule that was violated by the RTQ Recipe The current group of machine setpoints being used
CTQ Name The CTQ that the parameter affects Operator The operator currently responsible for the machine
Take Action A link to a document displaying the procedure to
remedy the RTQ alarm (optional)
CTQ Production Unit History
Each time the machine produces a unit to be tested, the box RTQ Status
turns grey alerting the user that some tests must be made.
Clicking on the box initiates the test process. When tests are
Individual machine parameters that are known to affect product quality are
completed, the box color indicates the unit results.
displayed using colored blocks to indicate status according to run rules.
Dark Grey Unit in production
RTQ Explorer Compares machine parameters for good and bad product
Light Grey Unit complete, ready for testing
Configure Set-up RTQ explorer display for current work order
Green Unit passed all tests
Reset Clears run-rule alarms for all RTQ status displays
Red Unit failed one or more tests
Green Yellow / Start-up unit, do not count Status Blocks Machine parameters displayed using colored bars to show
status according to run rules, and the CTQ affected
Green Yellow X Scrap unit, do not count
Black Spare space, not a unit
Failed CTQs Units Produced CTQ Analysis
A log showing the CTQs that failed in the current work order. A summary of the statistics for the current work order. A window displays control charts of the CTQ results for the current work
order. Each CTQ that has numeric results is displayed in a scrolling
Total The total units produced for the current work order
Prod Unit ID This is the production unit that failed a CTQ test
Passed Units produced on the current work order that passed Bars Groups of CTQ test results
CTQ This is the name of the CTQ that failed
Failed Units produced on the current work order that failed Bell Curve The natural distribution of the CTQ test results
Actual This is the measured amount of the failed test
Yield The percentage of passed units to total units Red Lines Upper Control Limit (UCL) and Lower Control Limit (LCL)
Target The desired value for the failed test
Green Line Mean value of the test results for the current work order
Link A link to a document displaying the information and
procedures to remedy the failed CTQ (optional)
Tools to find what affects product quality
Find Parameters that Relate To Quality
Imagine a production run where the produced
material consistently passes all quality tests, but
then something goes wrong and the material fails.
On a complex converting line, where do you begin
to look for the root cause of the quality failure?
Quality Management can help find what has
changed with a powerful tool called RTQ Explorer.
This feature compares and analyzes all monitored
parameters for the good and bad material and high-
lights the ones that have statistical variation. These
changed parameters become suspected RTQs and
are monitored using the run rules to see if they
influence the quality of the produced materials.
At the end of the production run, if the suspected
parameters are proven to relate-to-quality, they are
added to the data forms for future monitoring. So
that every time the product specification is run, the
machine operator will see the RTQ status block of
this important parameter displayed.
RTQ Explorer Display
The RTQ explorer works
by comparing two sets of
SPC data. Differences are
highlighted as potential
Selected Units The production units which had CTQ failures
Tested Units The production units which were made successfully with good quality
Comparison—Mean A bar graph that shows where the mean of the selected (failed) unit compares with the mean
of the tested unit expressed in terms of the tested standard deviation.
Green means that they were within one sigma of each other
Yellow means they were between one and two sigmas of each other
Red means they were more than two sigmas away from each other and is a suspected RTQ
Comparison—StdDev A bar graph that shows the ratio of the Selected standard units deviation to the tested units
standard deviation. A value of 1 indicates they had the same degree of variation.
Green means the ratio is less than one and the selected unit had less or equal variation
Yellow means the ratio is between 1 and 1.5 and the selected unit had more variation
Red means the ratio is more than 1.5 and the selected unit had much more variation and is
Reports to empower decisions
Report Title Function Used to
Production Order Show the quality data form results View the raw data that was entered during a
detailed by production unit for a given production run.
Quality Investigation Highlights the quality problems for a View only the raw data for production units which
Jacket given production order failed one or more of the tests.
TM Stats Test Method Statistics provides mean, Explore test data sets with active charts to
sigma, min, max # of points, Pp, Ppk, understand the quality results for a particular work
LCL , UCL , and dynamic control order.
PPK Performance Show the PPk of the test results. The Analyze and understand process capability and
six sigma range of a process total drive improvement efforts
variation where sigma is estimated by
the sample’s standard deviation
Certification Quality certification reports are based Retain a record of the quality test results made for
on work orders for particular customer a work order to verify compliance with customer
Custom Custom reports to user specifications Measure and report on results that drive
organizational workflows towards the achievement
of specific goals and objectives
Consulting Services For Rapid Deployment
Adopting quality management requires a commitment to
change. Stakeholders will use new processes and follow new
workflows for the organization to attain the benefits. To help
implement these changes, the Ei3 Corporation provides
consulting, change management and training services.
Ei3’s experience in applying best practices to the converting
industry provides a starting point for your quality program.
Every situation is different and requires individual needs to be
discovered to develop a successful implementation plan. Ei3
has a proven framework that applies a holistic approach to the Your Return On Investment
adoption of quality management. The framework address
both the technical and user aspects of a quality management Implementing a quality program is a challenging task for any
deployment. organization. Quality Management streamlines the process by
Quality Management can be delivered as a service by Ei3 providing a proven platform that incorporates established best
Corporation. This software-as-a-service business model en- practices to address the needs of most converting companies.
ables organizations to avoid significant costs and concentrate As an industry leader, Ei3 provides security and knowledge that
resources on their core business. Also, quality management Quality Management will enable achievement of higher yields,
works with existing quality programs and ERP systems to increased productivity and improved profitability.
provide higher yields. To learn more about how quality management can impact your
organization, contact Ei3 Corporation.
THE EI3 SUITE OF NETWORK POWERED SERVICES INCLUDES:
TECHNICAL SUPPORT TOOLS
Remote Service Platform Advanced security techniques create a safe environment for
troubleshooting experts to access machinery
System File & Document Keep critical machine programs and documents on-line and available for
Storage disaster recovery and troubleshooting sessions
Lifecycle Tracking Know when parts need to be replaced to plan maintenance activities,
increase performance and save capital
PRODUCTION SUPPORT TOOLS
Remote Monitoring & Review machine productivity data and trend key performance indicators
Production Reporting and view performance reports by shift, day, and machine
Downtime Tracking Identify root causes of downtime to maximize productivity
Recipe Management Upload machine settings, track recipe changes, and monitor efficiency
QUALITY SUPPORT TOOLS
Quality Management Augment existing quality procedures, drive workflows, discover and
monitor key parameters and report on product quality
EI3 HAS FLEXIBLE SERVICE PLANS TO MEET INDIVIDUAL PLANT NEEDS
Ei3 tools can be bundled together as a part of a complete service plan or can be used individually.
Starting an Ei3 service plan requires a set-up fee and broadband internet access. Flexible invoicing is
available including annual, quarterly or monthly schedules. Most plant sites can be activated in two to
four weeks. To enjoy the advantages of these programs, contact Ei3 for more information.
For more information contact:
136 Summit Avenue
Montvale, NJ 07645