Digital Quality System
10in6 replaces paper check sheets and quality binders with digital checks, real-time SPC monitoring and complete traceability. Each record is created when the check is done, and it's ready when an auditor or customer asks.
The problems DQS solves on the floor
Quality checks live on paper
Paper forms get filled in late, lost or skipped. Before an audit, someone spends days pulling binders.
Defects are found too late
Out-of-spec product travels downstream before anyone notices, and every operation it passes through adds to the rework, the scrap and sometimes a customer complaint.
Traceability gaps create risk
When a customer asks where a part has been and which checks it passed, the answer takes hours or days of digging through logs.
Every Module in our DQS
Select any module to explore what it does and how it fits into your quality operation.
Scheduled Quality Checks
Each check appears at the station when it is due, and the operator has to acknowledge and complete it before moving on, so checks aren't missed or filled in from memory at the end of the day. Conformance scorecards by line, area and operator update as results come in.
- Checks triggered on any schedule: hourly, per shift, per lot
- Mandatory acknowledgment, so a check cannot be skipped
- Instructions, reference images and pass/fail criteria attached to each check
- Alerts when a check is overdue or a result is out of spec
- A digital record with no paper to transcribe
Statistical Process Control (SPC)
Control charts plot each reading as it is taken, and Cpk is calculated for you. When a critical parameter such as a shaft diameter starts creeping toward its control limit, operators and engineers get an alert before a defective part is made.
- Xbar, R-chart and Cpk analysis for critical parameters
- Real-time alerts when data trends out of control limits
- Configurable warning and control limits per parameter
- Trends compared across shifts, lines and operators
- Integrates with Process Variable Collection for automatic data capture
Visual Inspection
Operators record visual defects on a touch screen at the station where they find them, tapping the defect type and its location on the part. Pareto charts by defect type, location, line and operator build from those entries, so root cause work starts from recorded counts.
- Touch-screen defect entry built for operators
- Classify defects by type, location and severity
- Repair or reject decision recorded at the point of detection
- Pareto charts by defect type, shift and line
- Defect locations mapped on product diagrams
- Trend analysis to separate systematic defects from random ones
Track & Trace
Operators scan or enter the unit or lot ID at each stage, and 10in6 builds its birth history: machine settings, operator IDs, timestamps, inspection results and raw material inputs. When a customer or regulator calls about a suspect lot, a recall or an audit, you can answer in minutes.
- Serialized, unit-level or lot-level traceability
- Every critical parameter tied to its unit or batch
- Material inputs, operator records and timestamps linked automatically
- Complete birth history reportable in seconds
- Sort and filter by serial number, date, line, operator or any other characteristic
Andon Alerts for Quality
An SPC alarm, a failed inspection or a repeating defect raises an alert immediately, and it escalates if nobody acknowledges it, so the issue is dealt with during the shift before it grows into a long defect run.
- Automatic alerts triggered by SPC alarms or failed checks
- Notifications routed to quality engineers, supervisors or management
- Andon board, email and SMS delivery
- Response time tracking: who acknowledged and when
- Escalation rules for unacknowledged alerts
- Full audit trail of every alert, response and resolution
Digital Auditing
Quality records are saved as they are created, so when an auditor walks in or a customer sends a request, the records already exist in a form you can search and present. Customers tell us auditors are impressed by how complete and easy to search their 10in6 records are.
- Records kept continuously, so there is no pre-audit scramble
- Inspection results, check conformance and defect history linked
- Filter and export records by date, line, product or lot
- Quality trends ready to show customers and auditors
- Supports IATF 16949, ISO 9001, SQF and customer-specific requirements
First Time Through (FTT)
The share of units that pass every production and inspection step without rework, repair or rejection on the first attempt, calculated automatically from quality check outcomes and scrap records.
- FTT by line, shift, product and operator
- Shows which operations or products drive the most rework
- Trends over shifts, weeks and months
- Measured first-pass loss for ranking improvement projects
- First-pass losses count toward the OEE Quality Rate
CMM Integration
Results from your Coordinate Measuring Machine (CMM) come into 10in6 without re-entry, so quality engineers and auditors see a part's dimensional results in the same record as its checks and history. Sold as a separately licensed add-on.
- Automatic capture of CMM measurement results
- Tied to specific units, batches or jobs in the production record
- Dimensional quality data alongside OEE, traceability and quality checks
- Supports major CMM brands and common output formats
Quality Alerting
After a defect is found, post an alert such as "surface defect, check all parts" to the machines or workstations where it could happen again. Operators on every shift see it at their station, confirm it, and keep checking for the defect while the alert is active.
- Active quality alerts displayed at specific machines or work centers
- Operator acknowledgement required before starting or continuing production
- Known issues and required checks shown to prevent recurrence
- The same alert seen by every shift and operator
What a missed check or a lost record costs
A defect that gets past the line, a missed check or an untraceable lot ends up as rework, scrap, a customer complaint or an audit finding. A paper chart won't flag process drift while it's happening, and a paper record is hard to defend after the fact. The binders also get harder to manage with every check the program adds.
In 10in6, checks, measurements and defects are recorded at the station, with the operator and the time attached to each one.
- Spend less time "checking the checkers"
- Investigate root causes instead of fighting fires
- Answer customer audit requests from the screen
- Reduce overpack and label errors at the source
Real Result
"After moving quality checks to 10in6, it was the first time we had a good view of overpack. This one change has resulted in hundreds of thousands of dollars in savings."
Set up around how your plant runs
Standardized platforms expect the plant to change to fit the software. Do-it-yourself platforms leave your team to build and maintain everything. With 10in6, we configure the system around your equipment, codes and reports, and your team runs it day to day.
Your equipment, codes and reports
Your checks, intervals and forms set up per line and product, and traceability built around your part numbers and your customers’ requirements.
Your team runs it day to day
Operators, downtime and scrap codes, products and targets, shift schedules, checks, alerts, emailed reports and real-time boards are managed by your own people. Everyday changes need no support ticket and no invoice.
A project manager for the bigger things
New machines, new modules and custom reports go through a 10in6 project manager who already knows your deployment, so nothing starts from scratch. If you would rather we made everyday changes too, we can.
Still here years later
The system keeps being refined after go-live, and new capabilities are added without rebuilding it. Some of our customer relationships have run for 12 years, and 97% of customers say they would never go back.
“Our 10in6 Project Manager has been very responsive and the software is flexible enough to be configured to our specific needs.”
How the 10in6 delivery model works →
From the plants running DQS
"Before 10in6, customer audits were nerve-racking. Now we are proud to show our system and positive quality trends."
"The Track and Trace module has helped us significantly improve traceability. We can now respond to customer requests in minutes."
"Quality, Engineering and Maintenance are all using the same data, working with a more united focus on issues."
The other two 10in6 systems
See how 10in6 fits your quality program
Tell us which checks you still run on paper and which standards you audit to. We'll work out which DQS modules would cover them and what they would cost.