Looking for a good mechanical inspection software package

J

just67horns

#1
We're looking for a good mechanical inspection software package for our factory. We want to record numerous variable and attribute data points to an inspection master (taken from Kcc's on the print) and then, later, generate typical metric data from it (pareto of defects, PPM, etc, the basics. I'm interested specifically in packages that we can buy and install rapidly, as I do not want a custom package, but off the shelf will do.

What do you use?
Thanks in advance.:bigwave:
 
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ScottK

Not out of the crisis
Staff member
Super Moderator
#2
I've used PQ Systems' SQCPack in the past to record test data for both variables and attributes.
I was with a small company and I equipped three standalone workstations.
I was quite happy with it.
 
J

just67horns

#3
not quite

That doesn't do it. SPC we have. We need to record inspections at high volume and document and summarize all of it. I need to report how departments, processes, products all are performing for manangement review input. We need to review statistics on these processes and note where are problems are. We need to be able and recall these specific jobs and the records of the inspections, to know who inspected it, what data and date. I know this is just a big database with reporting capabilities, but, rather than custom programming an access like application, I would like to know if someone is using a bought package?

Thanks
 
J

just67horns

#4
bump

help! Any more input here is appreciated.
How about you tell me where you record your inspections?
 

apestate

Quite Involved in Discussions
#5
Doesn't exist.

From what I gather you are talking about a software package that will database specifications and allow inspection "check sheets" to be either computerized or data-entered.

Oh well. The secret is being able to classify specs and tolerances into discrete data that can be worked with digitally. Once that is done, the whole project is viable within Microsoft Office. The real obstacle then becomes transferring data into the new format.

What is the volume of your inspections? What is the volume of part numbers on file, and approximately how many specifications per blueprint? Do you have a PPAP or initial sample inspection report process for new orders?

I realize you are looking for something off the shelf. If it exists, I would be piqued to know what it is. I would love for something like this to be available. The possibilities are exponential.
 

apestate

Quite Involved in Discussions
#6
66horns

I did some searching because it seems absurd that this doesn't exist already. Take a look at some of the info through the following link:

http://www.google.com/search?hl=en&lr=&as_qdr=all&q=checksheet+site:plex.com

This company seems to have an ERM product with numerous modules, one of which is a specification database.

What we currently use, and what I've seen for the most part, is MS Excel based inspection sheets. This is done well when the entire PPAP package is combined into one workbook of many sheets. The specifications are numbered and entered into the ISIR sheet, and the check sheets are linked to the data already entered. The sheets themselves are actually forms and are printed off. Data collection is written onto the hard copy and these check sheets are then filed into filing cabinets, where they are for all intents and purposes lost.

The place I work at currently doesn't even go this far. The inspection sheets are in Excel, each part has its own file. The file is a basic form and each time we create a new inspection check sheet, we re-enter the data.

One place I worked at had an electronic data collection system. Each machine had a computer terminal, and the setup machinist would put in the critical dimensions to be checked, a frequency, gage to use, etc. The electronic checksheet would ask for inputs based on the frequency. It was a constant development process that I'm sure grew beyond budgets, I didn't stick around to see.

These setups all have deep problems.

The major problem is the fact of filing cabinets. Once a check sheet goes into a filing cabinet, it is gone. What I mean is, you can only find that check sheet by part number. You cannot find that check sheet by gage number, by operator, by inspection result, by job number, etc. There may be ways around this if something like JobBOSS, Vista, E^2 or etc. are in use, but none of this is practical.

Another problem is the fact of poor data quality. Metric to inch conversions are incorrect, errors of data entry are prevalent, and poor inspection planning is done by operators and quality techs who are generating check sheets and ISIR paperwork by the reams.

We currently have a directory of Excel checksheets with 10,000 part numbers. This entire body of work could be lost right now and the operation would suffer absolutely no significant quality or productivity loss. It's tempting because they would certainly develop a different approach if offered a clean slate.

The idea of formatting specifications and tolerances for databasability came about because of errors in converting from metric to inch.

At the time, I was working for a company that had a complete PPAP and checksheet package together in Excel files. The format for specifications, tolerances, targets, and notes, however, was not databasable. It was entered as text, such as '1.25" +/- .020' or 'OAL 12.625 TARGET 12.680'.

Many parts were dimensioned in metric, and it was necessary for the quality manager to manually convert dimensions. The quality manager did not do this correctly in most cases so a spreadsheet for the purpose was developed. Quite simple, really. I'd get the correct data rounded to .0001" and update the check sheet.

However, there are many different types of specifications and many different types of tolerances. The conversion only worked for linear dimensions that were toleranced with a uni- or bi-lateral tolerance, range dimensions had to be handled differently.

After a little more work, it became possible to convert dimensions and their tolerances whether or not it was specified as a range. Using concatenate functions, the tolerance could be re-built. Inputting english inch specifications in a certain format (.5; "; +.03; -.00) would output a string of data in metric, and any portion of that string (12.7mm +.08 -.00) could be updated or modified individually. This concatenation would allow the data to be formatted for databasability in data entry and then automatically formatted for readability in form creation.

After a while of thinking about this, a complete breakdown of specification formats was developed for mechanical inspection.

In a little while, it should be possible to create a system that would automatically create check sheets, allow inspection results to be collected or entered electronically, allow measurement uncertainty and calibration results to be incorporated into targets for manufacturing, allow manufacturing results from one process to feed into the next one downstream, allow absolute traceability of all measurements and total positive recall to be accomplished, allow statistical analysis of inspection results, allow automatic lookup of standard dimensions and tolerances from tables, allow interface with ERM software, and interface with CMM, CNC, and CAD systems.

The main obstacle to accomplishing this is the great momentum of paper based inspection reporting. Of the 10,000 part numbers we currently carry inspection check sheets for, the average number of specifications per blueprint is approximately 22. Given the distribution, we estimate that 220,000 specifications +/- 25,000 are on hand. Given a guestimate of the time it would take to enter all these dimensions, specifications, and tolerances into a discrete data format, it seems it would take someone 12 months of steady data entry work to bring the company up to speed. In the US, based on this estimate, this would cost a manufacturer about $25,000. In the East, this could probably be accomplished for $10,000 in 2 or 3 months.

If an ERM software company provided this software, the cost would probably be very high. Each seat for data collection would cost extra. The universal upgrade would be astronomical.

I am young, and inexperienced. I have not seen a software package that can remove the filing cabinets from manufacturing. If it exists, it would be fascinating.
 
J

just67horns

#7
Hey, What really burns me up is that I know a package such as I want does exist! I should have mentioned, take a look at www.net-inspect.com


It is a very nice, web based solution. My IT department has decided that because the data is transmitted via the web, it is "insecure". He said that and management kaboshed the program. If they only knew how the federal reserve system processes his paycheck and all his hand written checks, maybe he would change his tune, but, He killed it...
 

apestate

Quite Involved in Discussions
#8
66horns

Sorry to hear about the paranoia regarding security putting the kabosh on your plans. Had you actually used net-inspect? Do you know what the price range is for a typical solution?

It's really easy to accomplish this within MS Office though. All you have to do is input your specifications and tolerances in a well-defined format. Do this once during the first article or revision change process and your entire documentation package is updated. While paper-based, you then have the perfect check sheet.

Take this setup and input your dimensional results using an Excel or Access form, and you can create a database of inspection results.

Of course, if your IT guy is likely to think his monitor got a computer virus because the speaker magnetized the tube, you're probably not in luck.
 
Last edited:

apestate

Quite Involved in Discussions
#9
I challenge anyone to show me a real specification database for mechanical inspection.

How many job shops are out there doing inspection and reporting of characteristics from their mechanical drawings? Are 100% of those job shops doing this on paper?

Ok, I have a blueprint. There are 36 specifications on it. The part is a big wheel stud for a TS-16949 company. It goes like this 1.75 +/- .030, 1-1/8 16 UNS LH; PD 1.075-1.078, R .020-.030, RA 32 max, 15 degrees +/- .5 degrees, etc.

Is there any supplier on Earth that could do the entire PPAP and production run without paper? Is there any supplier on Earth that could calibrate their pitch micrometer, see that it is reading .0005" high, and then instantly check the inspection results of the entire batch to see if any of the parts were out of tolerance?
 
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