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Real-Time Quality Monitoring with IoT Integration
An automotive parts manufacturer was losing $50K+ monthly due to quality defects discovered late in production. Manual quality inspections created data entry backlogs, and production metrics were only available at end of shift, making it impossible to catch issues early. Paper-based inspection reports were difficult to analyze for trends.
We implemented an end-to-end quality control automation system integrating IoT sensors on the production line with real-time dashboards and automated alerting. The system captures measurements directly from inspection equipment, applies statistical process control rules, alerts operators to deviations, and feeds data into their ERP system for traceability.
Project delivered in 12 weeks across 3 phases: Phase 1 (Weeks 1-4): Sensor integration and data collection pipeline Phase 2 (Weeks 5-8): Real-time dashboard and SPC rule engine Phase 3 (Weeks 9-12): ERP integration and automated reporting We integrated with 24 inspection stations across 3 production lines, capturing 50+ quality metrics per part. The system includes tablet-based digital inspection forms for visual checks.
Production data errors decreased by 65% through elimination of manual data entry. Defect detection time improved from end-of-shift to real-time, reducing scrap costs by 40%. Quality engineers now spend 15 hours per week analyzing trends instead of compiling reports. The system has prevented an estimated $180K in defect-related costs in the first year.
Key Outcomes: