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The hype around "big data" has mainly aimed at niche market sales without delivering expected benefits. Similarly, the business world's obsession with Lean Six Sigma has shown minimal returns on investment. In contrast, over the last 25 years, I've leveraged small Excel files to significantly cut costs and increase profits, often by millions of dollars, through a reliable sequence I discovered.

We explore two critical applications of AI and ML in quality management: predictive quality analytics and automated quality inspections.

Statistical Process Control (SPC) is evolving to not just detect defects, but also to predict and prevent issues. Modern factories use more sensors and collect more data, allowing SPC to analyze real-time patterns and forecast potential issues.

In today's tech-driven world, companies use software to collect data, but the analysis can be flawed. Charts with only specification limits, arbitrarily chosen warning and action limits, and misused Process Behavior Charts contribute to misinterpretation.

The Digital Twin Consortium (DTC) Composability Framework provides a transformative approach to digital twin system development, focusing on interoperability, security, trustworthiness, scalability, and design reuse to align with businesses’ objectives and evolving needs.

Front-office operations offer strategic opportunities for continuous improvement. Automating tasks can maximize effectiveness, free up senior employees, and lead to significant improvements in productivity and profitability.

Quality starts with requirements. Conformance to requirements is important, but not enough. The quality of the requirements is equally critical. An effective quality management system ensures that requirements are not only present and up to date, but also adequate for creating quality.

Manufacturing compliance goes beyond ticking boxes; it's about trust and excellence. Small manufacturers can navigate complex regulations by understanding compliance history, using technology, and implementing effective strategies for success.

Design of Experiments (DOE) helps improve products and processes more efficiently, providing a comprehensive understanding of influences on the end result.

In-process verification uses high-tech tools like 3D scanners and laser trackers on the factory floor to monitor products as they're made, allowing instant analysis and immediate problem-solving.