Imagine a shop floor that operates as smoothly as a perfectly synchronised orchestra, with every component in harmony and not a note out of sync. To achieve this, you would need a maestro who can fix not just slip-ups without missing a beat but also anticipate potential flaws before they disturb the rhythm. This is the promise that digital Quality Management System (QMS) brings to the realm of smart manufacturing, or Industry 4.0. In fact, the quality aspect is so pivotal to modern manufacturing that it gave rise to Quality 4.0, a term referring to the future of quality and organisational excellence in the context of Industry 4.0.
A digital QMS is the silent conductor that harmonises every element, from sensors, Manufacturing Execution Systems (MES), and enterprise systems, to deliver flawless outputs. It helps seamlessly weave quality into every aspect of production, like data, devices, processes, or operations. By drawing on real-time production data, IoT sensors, and enterprise systems, digital QMS becomes the backbone of smart manufacturing. By embedding quality directly into the operational fabric, manufacturers create intelligent environments capable of early deviation detection, automated corrective actions, and continuous traceability.
Not surprisingly, “Quality remains an AI use case frontrunner”, according to a recent industry report. As per this report, 48% of the survey respondents plan to use Artificial Intelligence (AI)/Machine Learning (ML) to improve quality. In a highly competitive sector where product quality defines customer experiences, digital QMS cannot be ignored any longer, as it comes with key add-on benefits. Here is a look at a few benefits.
making real-time quality a reality
Operational visibility is vital to decision-making and agility in production lines. This level of insight is possible only when real-time data is continuously available and evaluated against established quality parameters to maintain reliable compliance. Digital QMS enables this access to decision makers, facilitating agile interventions with greater precision. Another industry report notes that 52% of manufacturers have equipped shop floor workers with electronic devices, enabling greater involvement in operational decision-making. This is powered by a combination of technologies, including a digital QMS that ingests real-time data and delivers end-to-end insight. A digitised quality approach has the potential to boost productivity by 10-15%. Overall, it is a significant shift from reactive to proactive quality management.
enhancing traceability and compliance
Manufacturers often have multi-site or distributed geographical operations, and maintaining quality consistency across these is a challenge. Also, they are governed by applicable regional regulations, with sustainability being a key aspect. Shifting to a digital QMS ensures centralised quality processes and streamlined workflows with automatic transparency required for audit trails. End-to-end traceability of actions taken against documented processes is mandatory under ISO and similar quality certifications.
An AI-driven QMS strengthens supplier management by streamlining supplier evaluation, risk assessment, real-time communication, periodic audits, and much more. This is a key benefit, considering that product recalls were on the rise, with 50% of the recalls attributed to supplier issues. Additionally, it strengthens compliance across the entire production lifecycle. Change control is a huge part of quality assurance in manufacturing. Changes could be due to material, process, or technology upgrades. These changes are automatically reflected in the workflows, with necessary approvals to ensure traceability. And when it comes to non-conformances, a digital QMS facilitates easier data-driven root cause analysis by cross-referencing quality data. Overall, it results in critical capabilities, such as scalability and agility, for enhanced responsiveness to market changes.
optimised Corrective and Preventive Actions (CAPA)
As opposed to time-consuming traditional CAPA workflows, automated CAPA workflows of a digital QMS, powered by AI, work more efficiently to identify risks based on patterns, leverage predictive analytics, and prioritise corrective actions. This approach reduces downtime and repeat incidents, as the system continues to learn on the go. It also helps with predictive maintenance and improves Overall Equipment Effectiveness (OEE).
a note for the future
A study by the Boston Consulting Group (BCG) lists predictive quality, digitised SOPs, automated root cause analysis, and machine-to-machine self-adjustment of parameters among the top Quality 4.0 use cases driving improvement across the value chain. It only proves that digital QMS is now a strategic imperative for smart manufacturing, transforming quality management from a mere compliance function to one that fuels innovation, drives competitiveness, and builds resilience. As manufacturers aim to achieve zero-waste production, digital QMS will enable them to consistently deliver compliant quality outcomes.
how can Infosys BPM help?
Infosys BPM’sadvanced QMS for manufacturers covers the entire quality value chain, empowering manufacturers to enhance their quality initiatives for achieving consistent quality outcomes. From quality planning to compliance and certification, our services enable manufacturers with actionable insights and streamlined processes that enhance operational performance and competitiveness.
