AppsProduction & quality

Line defect rates

Defect rates are tallied per line from production results and in-process inspections. When a line crosses the control limit, you see the input lot and defect type with it, and record the investigation from the same screen.

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Quality control / Live

Line defect rates

8 lines reportingDay shift / 06:00–14:00

Overall defect rate

1.26%

-0.18 pp vs yesterday

Lines above 3.0%

Filling line 3

Units reworked

384

0.6% of output

Scrap cost

$2.52K

38% of weekly budget

Control limit 3.0% / sorted by line

Input lot	Defect type	Defect rate	Disposition
M260907-04	Viscosity drift	0.62%	In control
P260907-11	Temperature variance	0.18%	In control
F260907-08	Cap seal	3.84%	Immediate action required
L260907-06	Label position	1.16%	Watch
B260907-03	Carton crush	0.71%	In control
C260907-09	Barcode readability	0.94%	Watch
W260907-12	Underweight units	0.37%	In control
S260907-14	Film tears	2.26%	Effectiveness verified

Selected line diagnosis

Filling line 3

F260907-08 / Cap seal

Immediate action required

3.84%

Control limit: ≤ 3.0%
Variance: +0.84%p

Last 8 SPC checksOut of limit

Defect Pareto

Seal56%

Fill27%

Label17%

Recommended action

Hold input lot F260907-08 and investigate Cap seal.

Rule
Line defect rate > 3.0%
Over limit, show input lot
Lines over the limit
Past 3.0%, the line is flagged along with the input lot behind it.
On each production result
From
inline AI OS
To
Quality lead
Subject
Over-limit alert email
With every production result
Over-limit lines are emailed to the quality lead right away.
AI handles it
Quarantine the bad lot
Bad lots, quarantined
AI finds high-defect lots and quarantines them right away.

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App builderLine defect rates

Request
I want defect rates by line as they happen, and when one crosses the limit, to know which material lot went in.
App builder
Found 2 ARP modules. A few questions first.
What control limit should apply?
3.0% for every line, with an alert as soon as it's crossed
How should defect causes be grouped?
Seal, fill, label, visual, dimension, packing
Who should hear about rising defects?
The quality manager and line lead
App builder
Your app is ready to use.

App definition: Shape; Exception queue; Connected data; ARP ProductionARP Logistics & inventory; Rule; Line defect rate > 3.0% → over limit, show input lot; Automation; On each production result / Over-limit alert email → quality lead