Detect bad parts before they are even made! A revolutionary advancement that will change the manufacturing industry.

1. Challenging the Paradigms for
Quality Assurance
OES Technologies
www.OEStechnologies.com

2. Bad processes can make good parts
It’s true, good parts can be made from bad processes, but
how do you know when this does or doesn’t happen?
… should you be satisfied with this?

3. Tier One: a very demanding business
• Pennies per part price
• Parts per second speed
• Zero defect quality tolerance
Even one faulty product can result in expensive consequences such as
product recall, diminished reputation, or worst of all, lost future contracts.

4. Quality testing
Current practice:
Companies have been taught to rely solely on inspection methods
and devices to detect any bad products before they are shipped. The
underlying assumption is that a bad part can be produced at any
time and that catching these parts before they go out to customers
is priority.
• Dimensional inspection
• Visual inspection
• Sample inspection
…all have their shortcomings.

5. Inspecting the part
Visually the pipes look identical.
…Wouldn’t you like to know that the second one was
produced with a 56% increase in pull force during the
mandrel forming process?

6. Quality Testing ‐ Shortcomings
1. Limited to what can be visually seen and measured
2. Does not test hardness or thickness
3. Sample batch testing allows bad parts to slip by unnoticed (meaning
faulty parts get to your customer)
4. Costs time and money to undergo procedure
5. Does not test for variation in strain, stress, displacement, etc.
experienced by the part during forming
6. Allows bad processes to continue, risking part quality and catastrophic
failure
Adds NO value to your part or process!

7. Time for a change
Why then are we continuing to inspect finished parts,
risking downtime, machine failure, and shipping defective
products?
There is finally a better way!
Progressive companies are leading the shift by putting
more emphasis on refining and improving the
manufacturing process itself.

8. The NEW method:
Process Variation Monitoring
Focus on the PROCESS, not the finished Part.
If a process is known to be capable of producing only good parts, and the
process is consistent and repeatable, then the output of good parts will be
consistent also.
It’s simply about determining the quality and stability of the process.
Establish a good process.
Monitor that process.

9. A Good Process
A good process is a process that is incapable of producing a
bad part
… unless something in that process changes.
A good process is an engineered process.
A good process is an OES monitored process.

10. Monitor the Process
Monitoring the process for deviation, rather than checking
the parts for flaws, is an entirely new way of looking at
quality assurance.
Catch problems at the source and either alert the operator
or stop the production run.

11. Forming Example
The fail signature shows a process outside of the calculated
learn curve.
The result in this case was a collapsed end form on a
brake tube.

12. Mandrel bending example
PVM technology detected a 185% increase in pull force during the
production of the sixth tube.
This early warning alerted the operator of an incorrect alignment,
which had caused a wrinkled tube to be produced.

13. Tapping application:
Monitoring Spindle Motor Current to detect worn or broken taps.

14. Signature Analysis Techniques:
• Peak
• Area
• Envelope
• Force (Strain) vs. Distance (Position)
• Force (Strain) vs. Time

15. Tooling example
In-process monitoring of every tool cycle is critical for the detection
of process variation that may produce defective products or cause
catastrophic damage to the machine.

16. Other applications?
“Any time force is used to form, shape or fasten a product,
the strain, load, or displacement experienced by the
machine can be a useful indication of the product’s quality,
provided you have a good process.”

17. Benefits of Process Monitoring
• In‐process monitoring on 100% of parts
• Capture defects at the source prior to parts moving to next stages
• Manage maintenance to reduce costs and increase operational efficiency
• Catch hidden defects undetectable by visual or dimensional inspection
• Puts the focus on the process – sustainable gains in efficiency, scrap
reduction, and quality
Adds value to the process,
without adding cost to the part!

18. The OES Advantage
Inspection method… Defects are found after they happen.
(measures the part)
SPC method… Defects are found as they happen.
(measures the part)
The OES PVM method… Defects are found before they happen.
(measures the process)

19. OES ForceWorx
Process Signal Conditioners ‐ Provides force feedback for manufacturing,
assembly, on‐line processing or product testing.
PSC 100 PSC 200 PSC 300 PSC 500
SENSOR OPTIONS Force, Strain Force, Strain Force, Strain Force, Strain,
0‐10 VDC
ANALYSIS N/A Threshold limits Threshold limits Threshold limits
USER INTERFACE N/A Trim pot set points LCD/user buttons LCD/keypad
ANALOG OUTPUTS Continuous (0‐10 VDC), Continuous (0‐10 VDC), Continuous (0‐10 VDC), Continuous (0‐10 VDC),
Peak hold Peak hold Peak hold Peak hold
DIGITAL OUTPUTS Low threshold Low threshold Low threshold
N/A High threshold High threshold High threshold
COMMUNICATIONS N/A N/A N/A Optional

20. OES ForceWorx
Process Variation Monitors ‐ Provides dynamic in‐process monitoring of 100%
of parts, improving efficiency with lubrication
issues, tool wear, equipment adjustment, set up
verification, etc.
PVM 3000 PVM 3010 PVM 5000
SENSOR OPTIONS Force, Strain, Pressure, Motor Force, Strain, Pressure, Motor Force, Strain, Pressure, Motor
load, Displacement load, Displacement load, Displacement
ANALYSIS Input vs. Time Input vs. Time Input vs. Time,
Position / Distance
USER INTERFACE Via PC Via PLC LCD/keypad
ANALOG OUTPUTS N/A N/A N/A
DIGITAL OUTPUTS 4 4 4
DIGITAL INPUTS 3 3 4
COMMUNICATIONS Serial, Ethernet, USB Various PLC protocols Serial, Ethernet, USB

21. OES Inc.
4056 Blakie Road
London, Ontario N6L 1P7
Canada
Tel: 519-652-5833
Fax: 519-652-3795
forceworx@OES-inc.com