Do you know what percentage of defects are linked to human error? Research from ATKearney reports that it’s 68%.
People always introduce variability. Traditional manual quality inspections are inconsistent, often leading to defects that are expensive to fix and difficult to trace.
This article outlines how manufacturers can integrate human expertise with digital systems to achieve digital quality control.
The Case for Digital in Quality Control
Manual inspections have long been used for defect detection, but they’re reactive. Catching defects before shipping helps, but preventing them is better. Digital quality control systems, featuring real-time data collection and digital standard work, eliminate the variability that leads to defects.
Transitioning to automated inspections requires digitizing processes to ensure consistent work execution. From there, replacing paper inspection forms with digital checklists embedded within the standard work helps with data collection and downstream analysis.
Real-time dashboards make tracking pass-fail rates easier. Giving your quality teams the ability to get out of reactive quality efforts. That’s the “why” for digital. So how does it work? Here’s how one leading manufacturer saw success.
A Heavy Equipment Manufacturer's Transition to Automation
A Fortune 500 company, operating on a global scale, faced significant inefficiencies and errors in its frontline operations. Manual inspections, coupled with inconsistent data collection, contributed to frequent product defects, delays, and high operational costs.
They realized that human variability in their inspection process was introducing risks that threatened product quality and customer satisfaction.
Once they implemented a connected factory worker solution, the results were massive:
• $15,000 per hour saved in operational costs: Digitizing their quality control systems resulted in immediate savings by reducing labor hours spent on manual inspections and rework.
• 30% reduction in defects: By integrating automated inspection systems, defects were reduced significantly. This decrease was directly attributed to real-time data collection and consistent adherence to digital standard work.
• 20% improvement in production speed: The digital systems not only ensured quality control, but also optimized the overall production workflow by embedding checks directly into the manufacturing process. This integration cut down the time spent on standalone inspections, accelerating production timelines.
• Increased traceability by 35%: With automated systems logging data at every step, the manufacturer dramatically improved their ability to trace defects back to specific shifts, machines, or workers. This enhanced traceability prevented repeat issues and facilitated faster problem resolution, especially in the case of warranty claims or disputes.
• 100% digital record keeping: By replacing paper forms with digital checklists and logs, the company ensured that all inspections, corrective actions, and findings were stored in a centralized digital system, accessible across departments. This eliminated discrepancies in record-keeping and made compliance audits seamless.
If you want your transition to digital control to reflect those results, here’s the “how”...
How to Implement Automation in Quality Control
• Collect Real-time Data with Digital Checklists: Implement automated systems that capture data at every stage of production in a digital format. This eliminates delays and inconsistencies caused by manual inspections, enabling immediate corrective actions to prevent defects from compounding.
• Standardize Procedures: Replace paper-based processes with digital processes to ensure every worker follows the same protocol for each task. Standardization eliminates human error and ensures consistency across all shifts and production lines.
• Use Visual Dashboards and Alerts: Install visual dashboards to monitor real-time pass-fail rates and set up automated alerts to notify operators and managers of quality issues. This keeps everyone aligned with production goals and quality standards.
• Automate Worker Retraining: Set up automated retraining modules that trigger when defects or discrepancies are identified. This keeps workers updated on the latest quality standards without manual intervention or delays.
• Enable Proactive Maintenance: Use digital tools to detect early signs of equipment wear or potential issues before they lead to breakdowns. Proactive maintenance can significantly reduce unplanned downtime and costly repairs.
Transitioning from manual to digital quality control is essential for reducing defects, cutting costs, and improving customer satisfaction. With 68% of defects linked to human error, integrating human expertise with digital precision minimizes risk.
This shift builds a more resilient process and positions your workforce for long-term success.
The ATKearney research can be found here: https://www.kearney.com/service/digital-analytics/the-state-of-human-factory-analytics
