Thursday, September 25, 2025

Supply Chain Industrial Engineering - Supply Chain with Performance at Optimal Cost - Deloitte and More Premier Consultants


Prof. K.V.S.S. Narayana Rao had the vision to declare in 2013 that supply chain industrial engineering is a relevant task for industrial engineers and IE communities have to make the effort to develop it.

Supply Chain Industrial Engineering

Presentation made in a seminar "Recent Trends in Industrial Engineering" organized by  National Institute of Technology, Surat and IIIE Chapter Surat on 6 April 2013.


Part 1. Supply Chain - Industrial Engineering Tools and Techniques

2,361 views -  Uploaded on  8 Apr 2013

Part of the presentation on Supply Chain Industrial Engineering - A Proposal. Supply Chain Industrial Engineering Video (   • Supply Chain Industrial Engineering  ) has the remaining part of the presentation.


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https://www.youtube.com/watch?v=xsKJ7J_fEpc  

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Part 2

Supply Chain Industrial Engineering


1,550 views  8 Apr 2013

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https://www.youtube.com/watch?v=XSEWec1GrIQ

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Deloitte

Restructuring the supply base: Prioritizing a resilient, yet efficient supply chain

Resilience in supply chains held the spotlight for many years; however, the focus appears to be shifting back to efficiency as companies consider costs and margin pressures


23 May 2024

 • 

Deloitte Research Center for Energy & Industrials.

Optimizing the balance between performance and cost.


https://www.deloitte.com/us/en/insights/industry/manufacturing-industrial-products/global-supply-chain-resilience-amid-disruptions.html



Gartner

The Future of Supply Chain: Resilient, Agile, Purpose-Driven


February 26, 2021


Contributor: Sarah Hippold



The future of supply chain is to balance resilience vs. cost containment

One of the top priorities for companies now is to improve supply chains’ resilience and agility in meeting customer needs. At the same time, the pressure to contain costs isn’t going away as customers demand competitive pricing and CEOs watch their margins.


Most supply chain executives agree that their supply chains were primarily designed for cost efficiency. The challenge for supply chain leaders and their organizations now is to find new trade-offs between cost, speed and service in a changing landscape where uncertainty and higher customer expectations go hand in hand.


“Being purpose-driven is not just about doing no harm to stakeholders, but also positively amplifying benefits”


https://www.gartner.com/smarterwithgartner/the-future-of-supply-chain-resilient-agile-purpose-driven

McKinsey

Interesting Theme from McKinsey
Area - Productivity- Resilience

Resilience & Reimagination
Reimagining operations for productivity, resilience, and environmental sustainability through performance gains, flexibility, and speed



Supply Chain 

Industrial Engineering Process Charts

https://nraoiekc.blogspot.com/2020/09/supply-chain-industrial-engineering.html


Supply Chain Industrial Engineering - Bibliography

Productivity and Efficiency Improvement in Supply Chain Partner activities is practiced by Toyota Motors.

Productivity and Efficiency Improvement in Supply Chain Partner activities.

This applied IE was started by me in 2012. 

https://nraoiekc.blogspot.com/2012/01/supply-chain-industrial-engineering.html


Top Companies - Supply Chain Industrial Engineering Initiatives & Projects

https://nraoiekc.blogspot.com/2020/08/top-companies-supply-chain-industrial.html


SUPPLY CHAIN INDUSTRIAL ENGINEER - DOLLAR GENERAL

https://nraoiekc.blogspot.com/2023/05/supply-chain-industrial-engineer-dollar.html


Supplier Development - Supply Chain Industrial Engineering

https://nraoiekc.blogspot.com/2021/12/supplier-development-supply-chain.html


Supply Chain Industrial Engineer - Jobs and Job Descriptions

https://nraoiekc.blogspot.com/2020/08/supply-chain-industrial-engineer-jobs.html


Supply Chain Industrial Engineering - Some Ideas

Managing the Enterprise Supply Chain -  Industrial Engineering Management Chapter XI of the E-book

https://nraoiekc.blogspot.com/2021/10/supply-chain-industrial-engineering.html


Supply Chain Industrial Engineering - Supply Chain Productivity Improvement - Coca Cola

https://nraoiekc.blogspot.com/2019/12/supply-chain-industrial-engineering.html











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Operational Excellence - The Concept - The Practice

 

New

Breaking operational barriers to peak productivity
October 4, 2024 

The world needs more productivity growth. As a recent McKinsey Global Institute report  argues, it’s the best possible antidote to wealth inequality, inflation, and exploding debt and could provide crucial funding for the net-zero transition and improved living standards.

Over the past few years, three primary vectors of operational improvement have promised to raise productivity, but companies have often struggled to take full advantage of the potential:

The technologies collectively referred to as 4IR (or Industry 4.0) can improve performance across an entire value chain. But McKinsey research indicates that only 30 percent of organizations successfully scale and sustain digital improvement.

In 2023, research from McKinsey Digital estimated that gen AI could add $2.6 trillion to $4.4 trillion to the global economy. But by 2024, only about 5 percent of organizations said they could attribute at least 5 percent of their EBIT to gen AI.

Core operational excellence practices have a proven track record of creating significant improvement across variables ranging from cost reduction to employee retention—with the effects increasing over time. But data from the Operational Excellence Survey (OES) indicate that few organizations perform well across all five elements (Exhibit 3). Those that do are far more likely to sustain impact from 4IR and gen AI: operational excellence increases the value that technologies can generate.







Pic. Source.  https://www.linkedin.com/feed/update/urn:li:activity:7255912402729234432/





Excellence is Exceeding Customer Expectations.


Operational Excellence,  is a broader methodology that aims to improve the overall performance of an organization by aligning all aspects of the business with the company's vision and strategy. 

It emphasizes the importance of leadership, culture, and employee engagement to create and drive a culture of excellence and continuous improvement . Operational Excellence function can use all tools or techniques. Its  aim is to bring the entire organization together to strive for excellence.

https://www.reliableplant.com/operational-excellence-31886

https://instituteopex.org/what-is-operational-excellence/

https://www.ibm.com/cloud/blog/delivering-value-through-operational-excellence

https://www.forbes.com/sites/forbestechcouncil/2022/12/20/understanding-operational-excellence-and-the-continuous-optimization-of-it-operational-efficiency/

Excellence is Exceeding Customer Expectations.




Consultants




Operational excellence looks beyond cost reduction and process improvements towards the achievement of long-term sustainable growth. It is a mindset that embraces certain principles and tools to create a culture of excellence within an organization. Operational excellence means every employee can see, deliver and improve the flow of value to a customer.




Operational Excellence
Business Improvement
The focus of Operational Excellence is a hybrid of cost containment, operational throughput and a stable work force. The objective is a management team who are equipped to operationalise business strategy, implement change in their organisation’s processes and systems, and maximise value over the life of the asset.

Deloitte’s Operational Excellence offerings assist Operational Executives to operationalise business strategy, implement improvement and change in their organisation’s processes, systems and people, as well as to maximise the value over the life of an asset or organisation.  Operational Excellence includes:

- Environmental scanning & Strategic Context
- People, Performance and Culture
- Process Optimisation
- Supply Chain and Sourcing
- Asset Care
- Asset and Resource Optimisation
- Continuous Improvement
- Management Control Systems
- Organisational Redesign and Simplification
- System Capacity and Capability
- Social Labour Plan Commitments

Process Improvement Management - Process Productivity Management for Operational/Process Excellence - 3.6% Cost Reduction per Year


Companies

https://www.jpmorganchase.com/about/our-business/operational-excellence



27.10.2024





Sergio D'Amico, CSSBB  

I talk about continuous improvement and organizational excellence to help small business owners create a workplace culture of profitability and growth.
26.10.2024



Operational Excellence is  a system.0f 5 Pillars.

Here’s how the SQDCP five pillars can change your operations:

1️⃣ 𝗦𝗮𝗳𝗲𝘁𝘆:
- Unsafe conditions derail productivity and add costs.
- Focus on building a safe workspace, and watch efficiency rise.

2️⃣ 𝗤𝘂𝗮𝗹𝗶𝘁𝘆:
- Quality doesn’t cost; poor quality does.
- Set high standards and fix issues at the source.

3️⃣ 𝗗𝗲𝗹𝗶𝘃𝗲𝗿𝘆:
- Late delivery kills trust.
- Meet deadlines consistently to build client confidence.

4️⃣ 𝗖𝗼𝘀𝘁:
- Cost control isn’t about cutting, it's about using resources wisely. (Productivity of Resources - Industrial Engineering)
- Streamline processes to reduce waste, not quality.

5️⃣ 𝗣𝗲𝗼𝗽𝗹𝗲:
- People drive change; machines don’t.
- Train, motivate, and listen to your team. They’re the backbone of excellence.

Comment by Jim Beckham
Retired Director, Total Quality Management at JTEKT Corporation


I find the comments on priority an interesting discussion point. Let me contribute from someone who worked 14 years at one of the Toyota group of companies. We only used the first four, in priority sequence, SQDC. But it’s important to understand which stakeholder is impacted by each:
Safety- Employee stakeholder;
Quality - Customer stakeholder;
Delivery - Customer stakeholder; and
Cost - Shareholder stakeholder.

When management, an improvement team or a QC Circle follows the 8-Step Problem Solving method to make an improvement to one of these four areas, the solution for the improvement can not adversely impact the areas above. For example it a team was trying to improve productivity (Cost) and the improvement would make it more dangerous for the workers, or create a quality defect, or impact delivery, then the team would have to find another solution.


Additional Comment by Jim Beckham, Retired Director, Total Quality Management at JTEKT Corporation


Just to be clear, an improvement could be made that adversely impacts an area below and that would ok. For example, when fixing a Quality problem the solution can’t adversely impact Safety (which is above), but it could adversely impact Cost or Delivery (which are below). This is ok. It then gives the improvement team motivation to then solve the secondary Cost or Delivery problem. A little pain is always a good motivator for teams to take ownership and to improve.



Ud. 25.1.2025, 27.10.2024

Pub.  26.1.2023





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Productivity Planning - Learn from McKinsey Growth Planning

Breaking operational barriers to peak productivity
October 4, 2024 

The world needs more productivity growth. As a recent McKinsey Global Institute report  argues, it’s the best possible antidote to wealth inequality, inflation, and exploding debt and could provide crucial funding for the net-zero transition and improved living standards.

Over the past few years, three primary vectors of operational improvement have promised to raise productivity, but companies have often struggled to take full advantage of the potential:

The technologies collectively referred to as 4IR (or Industry 4.0) can improve performance across an entire value chain. But McKinsey research indicates that only 30 percent of organizations successfully scale and sustain digital improvement.
In 2023, research from McKinsey Digital estimated that gen AI could add $2.6 trillion to $4.4 trillion to the global economy. But by 2024, only about 5 percent of organizations said they could attribute at least 5 percent of their EBIT to gen AI.
Core operational excellence practices have a proven track record of creating significant improvement across variables ranging from cost reduction to employee retention—with the effects increasing over time. But data from the Operational Excellence Survey (OES) indicate that few organizations perform well across all five elements (Exhibit 3). Those that do are far more likely to sustain impact from 4IR and gen AI: operational excellence increases the value that technologies can generate.








Industrial Engineering leaders and managers have to plan productivity improvement or projects and studies for each financial year. Industrial engineers have to plan and achieve significant productivity gains year after year. These gains make possible increases in revenues and profits of the companies. As McKinsey authors write, if companies do not show growth, they will disappear. If IE departments cannot show productivity improvement they will diminish in importance and compensation. IE leaders have behave like entrepreneurs to identify productivity improvement opportunities at elemental level in operations. But, they have to be made Enterprise level contributions by horizontal deployment. It is important to remember that elements are common in many operations.

McKinsey authors write: Growing a business is a matter of do or die. 

Top growth leaders are methodical in asking and answering three crucial questions:

Where is my growth going to come from?
How do I grow now and tomorrow?
How do I set up my growth engine?

Productivity or industrial engineering leaders have to ask similar questions

Where is productivity going to come from?
How do I increase productivity this year and next year?
How do I set up my productivity engine?

Read McKinsey article:

https://www.mckinsey.com/business-functions/marketing-and-sales/our-insights/growing-faster-than-the-market


Important to read in detail.


Ud. 29.7.2025
Pub. 16.12.2019

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Wednesday, September 24, 2025

Automated Inspection - Introduction and Bibliography


Industrial Engineering - Role of Engineering, Mechanization and Automation


In process improvement study or projects, to do a task in the most productive manner, the most efficient manual method (best manual method), best mechanized method and best automation method are to be compared and the most productive method has to be employed. This comparison has to be done at element or suboperation level.

Source: Book: Motion and Time Study: Design and Measurement of Work, Ralph M. Barnes, 7th Edition, Chapter 18. Motion Study, Mechanization, and Automation.

Jidoka - Automation and Mechanization - Process Engineering and Industrial Engineering in Toyota Production System

Jidoka, a pillar of Toyota Production Systems advocates automation with human touch in all operations of a process to increase productivity of operators as well as that of total systems.


Automation of Operations in Flow Process Chart









Automated inspection uses machine vision, sensors, computer algorithms, and AI to automatically examine products, detect defects, and ensure quality in manufacturing. This process relies on cameras and software to analyze images and data for issues like misalignments, surface flaws, and deviations from specifications, offering greater speed, precision, and objectivity than manual inspection. Automated inspection lines integrate these technologies into production to maintain consistent quality, improve efficiency, and reduce costs across industries like automotive, electronics, and pharmaceuticals. 

How Automated Inspection Works
Data Capture: Specialized cameras and sensors capture images or other data from the product or component.
Image/Data Analysis: Sophisticated software, often incorporating machine vision and AI, analyzes this data to identify defects or non-conformities.
Comparison & Evaluation: The system compares the captured data against a "golden standard" or established parameters to flag any differences or deviations.
Actionable Output: The system can then categorize the defect, send the faulty item for rework, and provide insights for improving the manufacturing process. 


Key Components
Cameras and Sensors:
High-resolution cameras, 2D/3D imaging, and specialized sensors (like infrared) to capture detailed data. 
Machine Vision Software:
Software that processes images to identify defects, measure dimensions, and analyze surface properties. 
Artificial Intelligence (AI) and Machine Learning:
Algorithms that improve detection accuracy and identify a wider range of complex defects and anomalies. 
Robotic Arms:
Used to position components or move items through the inspection line, integrating the inspection with the production process. 
Benefits of Automated Inspection
Increased Accuracy & Consistency:
Reduces human error and provides more consistent quality control. 
Enhanced Speed & Efficiency:
Processes parts at speeds exceeding human capabilities, increasing production throughput. 
Cost Reduction:
Minimizes waste, recalls, and the need for large manual inspection teams. 
Improved Product Quality:
Ensures adherence to strict standards, reducing risks and improving customer satisfaction. 
Actionable Insights:
Provides data that helps identify root causes of defects and supports predictive maintenance. 
Common Applications
Printed Circuit Board (PCB) Manufacturing:
Detecting missing or misplaced components, soldering defects, and shorts. 
Pharmaceuticals:
Identifying particulate matter, cosmetic flaws, and ensuring proper fill levels. 
Automotive & Electronics:
Inspecting for surface defects, dimensional accuracy, and assembly integrity. 



Automated Inspection - Bibliography

2025

Unit 2 Automated Inspection System
https://egyankosh.ac.in/bitstream/123456789/27088/1/Unit-2.pdf



Parenteral Drug Association
Manual to Automated Inspection
https://www.pda.org/docs/default-source/pda-europe-education-presentations/2025/02_how-to-handle-test-sets/1.6-requirements-related-to-automated-visual-inspection.pdf?sfvrsn=8ffc9523_1

Evident Scientific
Evident designs and delivers automated inspection systems that meet the most challenging needs. Our systems utilize phased array and eddy current array.
https://ims.evidentscientific.com/en/automated-inspection

Automated inspection - Hexagon

Hexagon's solutions for capturing rich shop-floor data with automated inspection allows for quality assurance and process control.
 https://hexagon.com/solutions/automated-inspection  

Maximo® AI-Powered Inspection - Automated Visual Inspection
IBM
Boost Uptime with 24/7 Monitoring & Improve Quality All with IBM Maximo Visual Inspection. Unleash the Power of No-Code Computer Vision for Inspection Automation with IBM Maximo.
https://www.ibm.com/products/maximo/asset-inspection

Creating an Automated Inspection Line: A Comprehensive Guide
Published on: Nov 18, 2024
https://intelgic.com/creating-an-automated-inspection-line
 

MESH Automation

Our team at MESH Automation specializes in the design, construction, and programming of a broad spectrum of quality assurance solutions, including 2D and 3D vision inspection systems, non-contact laser measurement systems, tactile measurement tools, and advanced systems for mass flow or leak detection. We engineer these systems to be highly flexible, automatically adjusting to accommodate different products and fluctuating environmental conditions, effectively tackling your most challenging quality issues.

At MESH Automation, we deliver expert solutions in measurement, quality control, and marking/tracking. Whether integrating lasers, scribers, or print markers, we do so with unmatched professionalism. Moreover, marking is often followed by the need for precise tracking, an area where we excel, thanks to our comprehensive machinery and software capabilities.


Syntegon Technology 

Visual inspection machines
From manual inspection to intelligent automation – find the ideal visual inspection solution for you.

Visual inspection is a critical requirement for parenterals, mandated by regulatory authorities all over the world to ensure the highest product quality and patient safety. Syntegon is the strategic partner for both CDMOs or fully integrated pharmaceutical companies who want to achieve the most efficient inspection results.

Whether you require manual, semi-automated or fully automated visual inspection equipment, or integrated solutions with CCIT or Artificial Intelligence, Syntegon is your point of contact. With decades of experience and our Japanese heritage with a focus on quality, we are constantly developing innovative solutions to make your inspection processes ever more effective.



2024


What Is Automated Visual Inspection And How Is It Used?
Averroes
May 21, 2024

Automated visual inspection leverages technology to scrutinize products or equipment without human intervention, marking a significant evolution in quality control methodologies. 

Automated visual inspection is a technology-driven method that uses cameras, sensors, and algorithms to detect defects and ensure compliance with standards, highlighting its ability to operate faster and more accurately than human inspectors.

Applications in Industries

Semiconductor Manufacturing

Main Tools & Systems Used For Semiconductor Metrology (2024)
Averroes
May 20, 2024

Food Processing

Biopharma Manufacturing

Syntegon’s AIM Automated Inspection Machines offer the best quality inspection services powered by artificial intelligence. They  developed the  first Automatic Inspection Machine, the AIM275, in Japan in 1975. It  marked the first use of SD technology in particle detection, which has since become a staple of many pharmaceutical production facilities. Today, both camera-based inspection and SD technology can be integrated.

AIM 2|5 Series – Automated Inspection with Artificial Intelligence.

AIM 3000 ‒ Combining Visual Inspection, HVLD and Operational Excellence
Syntegon’s AIM 3000 guarantees high detection rates of moving particles by checking twice on two identical stations.

AIM 8000 Series ‒ AI-Ready, Versatile Platform for a Wide Variety of Products
The AIM 8000 is a flexible modular machine designed for customised solutions, with a vision system built to handle highly complex inspection requirements for particulate and cosmetic defects.


AIM 5022S: Automated inspection machine for syringes

Automated inspection machine for cartridges
Proven and reliable technology based on long-term experiences with dental and insulin cartridges



Automotive Manufacturing

A large, multinational automobile manufacturer responsible for producing millions of vehicles annually, engaged with IBM® to streamline their manufacturing processes with seamless, automated inspections driven by real-time data and artificial intelligence (AI).

As an automobile manufacturer, our client has an inherent duty to provide high-quality products. Ideally, they need to discover and fix any defects well before the automobile reaches the consumer. These defects are often expensive, difficult to identify and present a myriad of significant risks to customer satisfaction.

IBM worked with the client’s technical experts to deploy IBM Inspection Suite solutions to help them reduce defects and downtime while enabling quick action and issue resolution. The solutions deployed include fixed-mounted inspections (IBM Maximo® Visual Inspection Mobile) and handheld inspections (IBM Inspector Portable). Hands-free wearable inspections (IBM Inspector Wearable) were also made available for situations that required a head-mounted display.

Automated Inspection Solutions for Railroads


Mining

Medical Device Manufacturing
Construction
Solar Farms
Oil and Gas





April 10, 2024

TEST AND INSPECTION ASSEMBLY
Beyond the Human Eye: AI Improves Inspection in Manufacturing
By Ramūnas Berkmanas

Since implementing AI, a car seat manufacturer has seen a 30 percent reduction in defect rates.
Manual quality control methods limit the efficiency and effectiveness of modern manufacturing processes.
For one, manual inspection is too inconsistent. Due to factors like fatigue, human inspectors are prone to variability in their defect detection rates, which can range between 60 and 90 percent. Additionally, manual inspection is also slow. Manual processes often cannot keep up with fast-moving assembly lines, resulting in bottlenecks.

Common Use Cases are given in the article.



2021

Machine vision Based Inspection Productivity Improvement on Bottling Line - IE Case Study.


2020

AI Adds Continuous Improvement to Vision Systems
Cogniac helps manufacturers take vision system investments to the next level with AI-based models.
Peter Fretty
DEC 17, 2020


NEXIV VMZ-S3020 CNC video measuring system
December 11, 2020
Nikon Metrology

Automated Gauging for Process Control of Machining Operations

November 10, 2020


Gauging system provides 30% increase in manufacturing capacity
15 SEPTEMBER 2020
Manual gauging processes have created a bottleneck and preventing the achievement of  throughput necessary to achieve a part-manufacturing target at Olympus NDT. By automating inspection processes using a programmable shopfloor gauging system, the company eliminated the bottleneck and increased the output per hour with improved part quality and reduced scrap.


A New Programming Approach for Robot-based Flexible Inspection systems
William Brice Tekouo Moutchiho
utzverlag GmbH, 27-Mar-2019 - 226 pages
Preview

CNC Lathe In-Process Gauge

Supplier: Autonetics

The guage is a single part: the gauging head. The head was adapted for the FANUC robot tending the machine/cell. The robot grips the gauge as needed in a quick, automated tool change.  

Inspection Process
After the first roughing pass, the robot brings the measurement head into the machining envelop and positions it at the end of the part. A scan is then started and the robot move across the length of the part. Based on the scan, a 2D point cloud of the part is constructed. The point cloud is quickly processed and various diametrical and axial features are analyzed. The results are displayed on the Autonetics HMI. The measurements are automatically sent to the machine tool allowing the final cutting pass to remove the exact amount of material. After the last cutting pass is made the part is scanned by the robot with the gauge once more for a final assessment of the part.

Advancements in Automated Inspection - EWI - 2017
https://www.slideshare.net/EWI_engineering/advancements-in-automated-inspection

Flexible Measurement Systems - Robotic Inspection
https://www.dynalog-us.com/automated-in-line-gauging.htm

https://www.dynalog-us.com/case-study-world-first-calibrated-fms.htm
https://www.dynalog-us.com/case-study-katayama-automates-in-line-measurement.htm

https://www.amtcpl.com/software-based-automatic-multi-gauging-systems.html

https://blog.eaglegroupmanufacturers.com/precision-machined-parts-measuring-tools-every-cnc-shop-should-have

Gauging System Intelligent Process Control Software Automatically Updates CNC Tool Offsets
15 Feb 2018


Automatic Measurement in CNC Machines

Sipotek Machine Vision Systems

In Process Part Measurement - HaaS Tips - Video
https://www.haascnc.com/video/tipoftheday/ffzi6rwicuu.html

6 Factors to Consider Before Moving to Automated Inspection
A properly programmed automatic-visual-inspection system can significantly reduce the risk of bad inspections, and lead to reduced costs over time.
Dr. Helmut Hamfeld
JUL 05, 2016
https://www.machinedesign.com/markets/manufacturing-equipment/article/21832077/6-factors-to-consider-before-moving-to-automated-inspection

https://www.automation.com/en-us/articles/2009-2/automated-inspection-gaging-systems-improve-qualit

4 ways - Machine vision cameras or laser sensors integrated into equipment
2. Separate inspection station with Machine vision cameras or laser sensors
3. Turnkey systems with Machine vision cameras or laser sensors designed for specific component or family of components.
4. Robots to handle parts or cameras
https://blog.jrecorp.com/blog/four-types-of-automated-inspection-systems




Springer Handbook of Automation

Shimon Y. Nof
Springer Science & Business Media, 16-Jul-2009 - Technology & Engineering - 1812 pages

Automation is undergoing a major transformation in scope and dimension and plays an increasingly important role in the global economy and in our daily lives. Engineers combine automated devices with mathematical and organizational tools to create complex systems for a rapidly expanding range of applications and human activities. The Springer Handbook of Automation incorporates these new developments and presents a widespread and well-structured conglomeration of new emerging application areas of automation. Besides manufacturing as a primary application of automation, the handbook contains new application areas such as medical systems and health, transportation, security and maintenance, service, construction and retail as well as production or logistics. This Springer Handbook is not only an ideal resource for automation experts but also for people new to this expanding field such as engineers, computer scientists, designers. It is edited by an internationally renowned and experienced expert.

Automating Quality Systems
J.E. Tannock


1988 - Report FMS - Automated Inspection

Four key conclusions can be made based on the information available about automated inspection in flexible machining systems.
1. There are very few FMS installations that have automated inspection fully integrated into the system. 
2. A major factor is the reluctance of management to invest large amounts of capital because of concerns about the length of the payback period.
3. Many vendors, user groups, and research institutions are actively involved in research and development in all aspects of automated inspection.
4. The trend in FMS automated inspection is toward controlling the process through in-process gaging and deterministic metrology.


Updated  24.9.2024, 29.9.2022,  23 Sep 2021, 17 December 2020
First published 16 July 2020
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Tuesday, September 23, 2025

Software Inspection & Testing Process Improvement - An Industrial Engineering Task

Inspection Activities - Operation Analysis - Process Improvement


It is interesting to note that in software engineering there is lot of emphasis on process improvement. Industrial engineers are not that active in software process improvement, even though there are some articles and papers by industrial engineers. But software field is more active in this area.

New.

Popular E-Book on IE,

Introduction to Modern Industrial Engineering.  #FREE #Download.

In 0.5% on Academia.edu. 11,600+ Downloads so far. 

https://academia.edu/103626052/INTRODUCTION_TO_MODERN_INDUSTRIAL_ENGINEERING_Version_3_0




Three Major Channels of Process Improvement.
1. Process Redesign by Process Planning Team.
2. Process Improvement Study by Industrial Engineering Team.
3. Continuous #Improvement by Involving Shop Floor Employees and All Employees.

Continuous Improvement - Employee Participation Principle of Industrial Engineering


2025 IBM Article

What is software testing?


Authors

Stephanie Susnjara

Staff Writer

IBM Think


Ian Smalley

Staff Editor

IBM Think


09 July 2025

https://www.ibm.com/think/topics/software-testing    - Very good information. Recent  2025


Software Testing

Carnegie Mellon University

18-849b Dependable Embedded Systems

Spring 1999

Authors: Jiantao Pan


Abstract:

Software testing is any activity aimed at evaluating an attribute or capability of a program or system and determining that it meets its required results. [Hetzel88] Although crucial to software quality and widely deployed by programmers and testers, software testing still remains an art, due to limited understanding of the principles of software. The difficulty in software testing stems from the complexity of software: we can not completely test a program with moderate complexity. Testing is more than just debugging. The purpose of testing can be quality assurance, verification and validation, or reliability estimation. Testing can be used as a generic metric as well. Correctness testing and reliability testing are two major areas of testing. Software testing is a trade-off between budget, time and quality.


Basic Practices for Inspection Improvements 

Paper "Looking for inspection improvements through base practices" by Ilkka Tervonen, Juha Iisakka and Lasse Harjumaa

1. INTRODUCTION

For inspection process improvement,  updating of checklists, implementation of new forms and the definition of new metrics for measurement data are being attempted. Improvement measures that are most relevant to the inspection process in the testing area are available in   the Testing Maturity Model (TMM) [1], Testability Maturity Model [4] and Test Process Improvement Model (TPI) [10].  

A new capability model tailored especially to inspection process evaluation and the search for relevant improvement suggestions is proposed in this paper.

Inspection in software field is traditionally defined in terms of steps such as entry, planning, kickoff meeting, individual inspection, logging (inspection) meeting, edit, follow up, exit and release [3],[6].

There are six defined goals in inspection process. 

(1) to identify defects in an artefact, 

(2) to estimate the quality of an artefact, 

(3) to improve product quality, 

(4) to provide data for software development  process improvement, 

(5) to provide the means for knowledge transfer, and 

(6) to improve the effectiveness of the software development process.


The suggested practices are classified into three sets. 

1): supporting activities, which help in carrying out an instance of the inspection process, the core set of activities  which are the essence of the inspection process implementation, and organisational activities, which ensure continuous improvement and efficient organisation of the inspection process. 

The supporting activities are

  • "Support with computer tools", 
  • "Maintain rules and checklists" and 
  • "Refine information”. 
  • The core set of  practices  include the activities 
  • "Check the preconditions for inspection", 
  • "Plan the inspection", 
  • "Find issues in the artefact", 
  • "Categorise defects", 
  • "Make corrections" and 
  • "Conclude the inspection".


The organisational set consists of the rest of the activities  

  • "Organise the inspection", 
  • Train the participants" and 
  • "Establish and improve the inspection process".



The  practices of the inspection process

  • Categorise defects
  • Make corrections
  • Find issues in the artefact
  • Plan the inspection
  • Check preconditions for inspection
  • Maintain rules and checklists
  • Refine information
  • Support with computer tools
  • Organise the inspection
  • Establish


Checklists, for example, are characterised as follows:

- checklists are tools to be used by inspectors; lists of topics which should be checked in a specific

artefact

- checklists are derived from rules

- checklists should be tailored to specific baselines and roles, for example

- checklists should be up to date

- focus on the discovery of major defects


SOME GENERAL SUGGESTIONS FOR INSPECTION IMPROVEMENTS

Researchers in the field of software inspection have been discussing the requirements for a reorganised inspection process [7], [9], focusing especially on reducing the number of logging meetings. In a previous paper [7] some new ways to organise an inspection meeting are presented. 

There are some general suggestions for improvements presented in the area of software inspection. 

Gilb [5], for example, introduces 24 key tips for improving the inspection process, and classifies them into eight groups: inspection strategy, entry conditions, planning, individual checking, the logging meeting, process brainstorming, exit conditions and inspection statistics. 


Some of the key tips 

Inspection strategy

* Make sure there are adequate standards for identifying defective practices.

*Give the inspection team leaders proper training, coaching after the initial training, formal certification and statistical follow-up, and be prepared to withdraw their licence to inspect if necessary.


Planning phase 

* Plan inspections well, using a master plan.

* Plan inspections to address the relevant purposes.

* Inspect early and often, while documents are still being written.

* Use sampling to understand the quality level of the document.

* Check against source and kin documents; check these for defects, too.

* Check significant portions of the material - avoid checking commentary.

* Allocate special defect-searching roles to people in the team.

Inspection statistics 

* Build or buy an automated software tool to process basic inspection data.

* Measure the benefits gained from using inspections.


References

[1] Burnstein I., et al., A Testing Maturity Model for Software Test Process Assessment and improvement, Software Quality Professional, vol 1, no 4, 1999

[2] Emam K., El J., Drouin J., Melo W., SPICE: The Theory and Practice of Software Process Improvement and Capability Determination, IEEE Computer Society, 1998

[3] Fagan M.E., Design and Code Inspection to Reduce Errors in Program Development, IBM Systems Journal, vol 15, no 3, 1976, pp.182-211

[4] Gelperin, D., and Hayashi A., How to support better software testing, Application Trends, May, 1996, pp. 42-48.

[5] Gilb T., Planning to get the most out of inspections, Software Quality Professional, vol 2, no 2, 2000

[6] Gilb T., and Graham D.: Software Inspection, Addison-Wesley, Wokingham, England, 1993

[7] Iisakka J., and Tervonen I., Painless Improvements to the Review Process, Software Quality Journal, 7, 1998, pp. 11-20

[8] i3GO, The URL of the Improved Inspection Initiative Group in Oulu is http://www.tol.oulu.fi/i3/

[9] Johnson P.M., Reengineering Inspection, Communications of the ACM, vol 41, no 2, 1998, pp. 49-52

[10] Koomen, T., and Pol M., Test Process Improvement: A practical step-by-step guide to structured testing, AddisonWesley, 1999

[11] Kuvaja P. et al., Software Process Assessment and Improvement, The Bootstrap Approach, Oxford, Blackwell, 1994

[12] Paulk M. et al., The Capability Maturity Model: Guidelines for Improving the Software Process, Addison-Wesley, 1995


Looking for inspection improvements through base practices by Ilkka Tervonen, Juha Iisakka and Lasse Harjumaa

Department of Information Processing Science, University of Oulu, P.O. Box 3000, FIN-90014 University of Oulu, Finland


News and Articles Related to Software Inspection Process Improvement


Welcome to ISTQB®

ISTQB® is the leading global certification scheme in the field of software testing.

As of Apr 2023, ISTQB® has administered over 1.2 million exams and issued more than 845k certifications in over 130 countries. With its extensive network of Accredited Training Providers, Member Boards, and Exam Providers, ISTQB® is one of the biggest and most established vendor-neutral professional certification schemes in the world.

ISTQB® terminology is industry recognized as the defacto language in the field of software testing and connects professionals worldwide.

Join our network of software testing professionals by becoming certified today!

https://www.istqb.org/

Sample Exam Answers

https://astqb.org/assets/documents/ISTQB_CTFL_Sample-Exam-Answers_v4.0.pdf

Glossary for Software Testing

https://www.ctqb.org/en/downloads/istqb.html?file=files/content/ctqb/downloads/istqb/Glossary-terms-version-3.7.pdf&cid=33119

https://www.linkedin.com/pulse/what-changed-new-istqb-syllabus-2023-40-hassen-dai/

https://github.com/jalizadeh/ISTQB-Exam-Questions   - Chapterwise




2025

A Reflection on “Advances in Software Inspections”

IEEE Transactions on Software Engineering

Mar. 2025, pp. 728-731, vol. 51

Authors - Adam A. Porter, University of Maryland, College Park, MD, USA  

Harvey Siy, University of Nebraska at Omaha, Omaha, NE, USA  

Lawrence Votta, Computer and Applications Consultant, Bellevue, WA, USA

https://www.computer.org/csdl/journal/ts/2025/03/10859180/23X96TmJ4Va


Evaluating large language models for software testing

Computer Standards & Interfaces

Volume 93, April 2025, 103942

Computer Standards & Interfaces

https://www.sciencedirect.com/science/article/abs/pii/S0920548924001119




Next-Generation Software Testing: AI-Powered Test Automation

IEEE Software

Jul.-Aug. 2025, pp. 25-33, vol. 42

Authors

Filippo Ricca, University of Genova, Genova, Italy  

Boni García, Universidad Carlos III de Madrid, Madrid, Spain  

Michel Nass, Blekinge Institute of Technology, Karlskrona, Sweden  

Mark Harman, University College, London, U.K.


Testing Research Software: An In-Depth Survey of Practices, Methods, and Tools

Nasir U. Eisty, Upulee Kanewala, Jeffrey C. Carver

https://arxiv.org/abs/2501.17739




2024

Software Testing Techniques and Levels in Software Development

December 2024  International Journal of Advancements in Computing Technology 2(1 February 2024):10-19

DOI:10.56472/25838628/IJACT-V2I1P102

Authors:

Samuel Gbli Tetteh

DePaul University

https://www.researchgate.net/publication/387460992_Software_Testing_Techniques_and_Levels_in_Software_Development

2023

ChatGPT and Software Testing.

by Ajay Balamurugadas

June 21, 2023 

https://www.thetesttribe.com/blog/chatgpt-for-software-testing/


How Will Software Testing Change In 2023?

Forbes Technology Council

Joel Montvelisky

Co-Founder and Chief Solution Architect at PractiTest-Test Management. OnlineTestConf founder and chairman.

Developers can test software elements and their own code early on, identifying and resolving errors earlier in the development process.

The testing automation market is expected to grow at a CAGR of 16.4% between 2022-2027. Organizations are investing  more resources in their automation infrastructure. Hiring technical testers  responsible for writing and maintaining company’s automation work is also increasing.


Testing In Production is Increasing

In DevOps methodologies, releases are happening as fast as possible, pushing the software testing efforts to the right side of the deployment threshold. Testing in production is being done and issue are being resolved in a live environment. 



2022

Nasscom - KPMG -‘Software Testing: Trends shaping the Industry’ shares a quick view of the global and Indian trends in software testing with insights for businesses, testing professionals & other stakeholders. It is designed to offer a thought on the industry and how digital transformation is blurring boundaries between development, testing and operations teams with special focus on testing.

May 2022

2021

https://books.google.co.in/books?id=Q30wEAAAQBAJ   




2020

https://books.google.co.in/books?id=hRwGEAAAQBAJ   


2017

Software Inspections and Their Role in Software Quality Assurance

July 2017    American Journal of Software Engineering and Applications 6(4):105

DOI:10.11648/j.ajsea.20170604.11

LicenseCC BY 4.0

Authors: Abdul Ahad

https://www.researchgate.net/publication/321649578_Software_Inspections_and_Their_Role_in_Software_Quality_Assurance



2015

https://books.google.co.in/books?id=cSpzCQAAQBAJ    



2009

Survey of Software Inspection Research - Sami Kollanus

https://benthamopen.com/contents/pdf/TOSEJ/TOSEJ-3-15.pdf

https://books.google.co.in/books?id=fgaBDd0TfT8C    


2008

Lasse Harjumaa, Ilkka Tervonen, Sirpa Salmela, "Steering the inspection process with prescriptive metrics and process patterns", Quality Software 2008. QSIC '08. The Eighth International Conference on, pp. 285-293, 2008.


2005

The ROI from Software Quality

Khaled El Emam

CRC Press, 09-Jun-2005 - Business & Economics - 296 pages

The ROI from Software Quality provides the tools needed for software engineers and project managers to calculate how much they should invest in quality, what benefits the investment will reap, and just how quickly those benefits will be realized. This text provides the quantitative models necessary for making real and reasonable calculations


Research Papers of Sami Kollanus on Inspection - around 16 papers

2004

L. Harjumaa, I. Tervonen, P. Vuorio, "Improving software inspection process with patterns", Quality Software 2004. QSIC 2004. Proceedings. Fourth International Conference on, pp. 118-125, 2004.


Lasse Harjumaa, Ilkka Tervonen, Pekka Vuorio, Product Focused Software Process Improvement, vol. 3009, pp. 62, 2004.


2003

https://wiki.c2.com/?SoftwareInspection


Books on Software Testing

https://books.google.co.in/books?id=zQg3EAAAQBAJ  


2001


A tailored capability model for inspection process improvement

I. Tervonen; J. Iisakka; L. Harjumaa

Abstract:

Software inspection is recognised as the most effective means of finding defects. In spite of its important role in software development, existing capability models have not addressed inspection issues or looked for inspection-related improvement activities to a sufficient extent. The inspection-tailored capability model presented provides a method for evaluating inspection process capability and supports the location of weak points in a company's inspection process. The first experiments reported are promising, and the evaluation process discovered correctly focused improvement ideas which were also agreed on by the company concerned.

Published in: Proceedings Second Asia-Pacific Conference on Quality Software, Hong Kong, China

Date of Conference: 10-11 Dec. 2001

Date Added to IEEE Xplore: 07 August 2002

DOI: 10.1109/APAQS.2001.990030

https://ieeexplore.ieee.org/document/990030/citations#citations



2000
A Path to Virtual Software Inspection

Henrik Hedberg
https://www.academia.edu/12219257/A_Path_to_Virtual_Software_Inspection


1999

Chapter 3 Using Formal Inspections in Software Quality Assurance

http://users.csc.calpoly.edu/~jdalbey/205/Resources/Inspections/UsingInspections.html

1998

Monitoring Software Inspections With Prescriptive Metrics

March 1998

Authors:

Ilkka Tervonen

University of Oulu

Juha Iisakka

University of Oulu

https://www.researchgate.net/publication/2409746_Monitoring_Software_Inspections_With_Prescriptive_Metrics


1995

Automating the Software Inspection Process

Fraser Macdonald

1995, Automated Software Engineering

https://www.academia.edu/48963309/Automating_the_Software_Inspection_Process


1986

Advances in software inspections

Michael E. Fagan

IBM Thomas J. Watson Research Center, Yorktown Heights, NY, USA

Published in: IEEE Transactions on Software Engineering ( Volume: SE-12, Issue: 7, July 1986)

Page(s): 744 - 751

Date of Publication: 31 July 1986

https://ieeexplore.ieee.org/abstract/document/6312976/authors#authors







Ud 23.9.2024, 23.9.2023, 23.9.2022, 23 Sep 2021

Pub 5 Dec 2020




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Labels:

Inspection - Quality Activities - Operation Analysis - Process Improvement

New.

Popular E-Book on IE,

Introduction to Modern Industrial Engineering. 

In 0.1% on Academia.edu. 11,600+ Downloads so far.

FREE Download from:

https://academia.edu/103626052/INTRODUCTION_TO_MODERN_INDUSTRIAL_ENGINEERING_Version_3_0


-------------------------


Lesson 126 of  Industrial Engineering ONLINE Course

Inspection Operations Improvement  Sub-Module of IE ONLINE Course -  Lessons
126 - 127 - 128 - 129 - 130 - 131 - 132


Focus on Quality Essential for Industrial Engineers

F.W. Taylor: It is to be ensured that no quality deterioration takes place due to increasing productivity by increasing speed of machines or that of operators. Inspection system has to be put in place first to prove that there is no quality deterioration due to productivity improvement interventions or attempts and redesign of processes.

Hence, industrial engineers have to document the quality level of each and every element of the process (step of the process) in the process chart. After implementing the process also, they have to record the quality data on the new process chart and thus should not give any chance for any person to say that quality has deteriorated due to productivity improvement.

Juran: “Just as the twentieth century was the century of productivity, the twenty-first century will be the quality century.”

Reimann (1992a), Director for Quality Programs, National Institute of Standards and Technology, U.S. Department of Commerce, in testimony to the U.S. Congress: “There is now far clearer perception that quality is central to company competitiveness and to national competitiveness.”

Inspection during processing and after processing are done to ensure that the parts or products are as per the specification. Customer also inspects before using. Inspection is an important operation in production and service activities.

Inspection is included as one of the five operations included in the ASME process chart for evaluating and improving it to increase productivity. Inspection operation has to be improved and its work station has to be improved. The handling the component is to be improved.

While the inspection procedure employed in this operation is analyzed for improvement, it is necessary to evaluate the self inspection done by the operator. The inspection done by the operator is at the input side as well at the output side. It is related to the material and it extends to tools, gauges and set up also.

In the case of transport operation, we always think of layout improvement at the plant level. Similarly, in case of inspection, we need to think of the quality management system and practices of the company. Improvement at the company level quality management practices, can be have a big effect on the productivity of inspection operations.

Read for more details on Taylor's focus on quality:

Illustrations of Success of Scientific Management - Bicycle Balls Inspection Example - Taylor


Engineering/Technology - Process/Operation Interface Industrial Engineering


Industrial engineers have to regularly get news regarding engineering and technology developments and assess their utility for productivity/performance improvement of processes in their organization.

Where utility is there, they have to do detailed investigation and incorporate the new technology element in their process and increase the performance. This is continuous engineering improvement of the process and is the responsibility of the industrial engineer. When the engineering change is carried out the design group will get acquainted with the new technology elements and will take steps to use it appropriately in their new design and major redesign projects.  Engineering - Industrial Engineering is a cumulative process. Each contributing their share in the design of products and processes and the knowledge is cumulated.

Inspection operation improvement related News

(Collection of current news - News, Information for Inspection Operation Analysis )

Modular gauging and holding fixtures with 3D-printed locators make the Coordinate Measuring Machine  sequence faster and more reliable.


AUG 13, 2020
The patented products are being supplied by Rapidfit. Gage fixtures are for inspecting automotive components after manufacturing. Holding fixtures support components as they are built into a vehicle and measured using CMMs or other metrology equipment. 



Analysis of Tolerances and Inspection Standards

The specification of tolerances or the standards of quality, accuracy, finish, and so on, that the operation must satisfy play an important part in the methods used to produce the part. In fact, in many cases, the requirements fix the method. The accuracy with which the diameter of a small shaft must be machined and the finish which the machined surface must possess will determine the machines that must be used, the number of cuts taken, and the feeds and speeds.

Hence, at the outset of any process/operation/methods study, it is important, first, that the tolerance requirements of the operation be known and, second, that these requirements be reviewed for correctness.  The assumptions are made that the operator is doing a job which will pass inspection and that the requirements as specified by the designer or the chief inspector are correct. Undoubtedly these assumptions are true in the majority of industrial operations, but enough important exceptions are encountered to make an analysis of tolerance and inspection requirements a point of primary importance.

Questions.

The following questions should be raised and, as always, answered only after careful consideration:

1. What are the inspection requirements of this operation?

2. What are the requirements of the preceding operation?

3. What are the requirements of the following operation?

4. Will changing the requirements of a previous operation make this operation easier to perform?

5. Will changing the requirement of this operation make a subsequent operation easier to perform?

6. Are tolerance, allowance, finish, and other requirements necessary?

7. Are they suitable for the purpose the part has to play in the finished product ?

8. Can the requirements be raised to improve quality without increasing cost?

9. Will lowering the requirements materially reduce costs?

10. Can the quality of the finished product be improved in any way even beyond present requirements?

Relation of Methods Efficiency Study to Quality.


Methods efficiency studies are made primarily for the purpose of eliminating waste and reducing costs. In so doing, however, it goes without saying that nothing should be done to impair the quality of the finished product or its salability. Because the methods efficiency engineer is interested in enhancing the competitive position of his company's products, he quite naturally must take a keen interest in the factor of quality. Products of superior quality outsell products of inferior quality, other things being equal; hence, an improvement in quality is always desirable, provided, of course, that it is necessary and useful quality. Any improvement that betters the functioning, appearance, or salability of the product should be constantly sought. Unnecessary quality, however, refinements that add to the cost of the product without in any way improving it, should be eliminated.

Sometimes it is difficult to decide whether a certain requirement is an unnecessary refinement or a desirable improver of quality. Such questions can be answered only after a thorough discussion of all of the factors involved. In general, however, because of the competitive condition existing in industry, any suggested improvement in quality that can be made without taking the product out of its price class should be adopted.

The methods efficiency engineer is in a good position to make suggestions that will improve quality. Because he studies a product in detail and considers thoroughly every factor connected with it, he is quite likely to discover ways of making the product better. In addition, because he eventually sets up working methods that are easy, efficient methods, and because he trains all operators to follow those methods, a higher and more uniform quality of workmanship results than where each operator is left to develop methods for himself. As a result, therefore, methods study tends to raise the quality of the finished product.

Results of Analyzing Inspection Requirements.


For machine work, the limits of accuracy within which the part must be machined are customarily specified on the drawing of the part. These allowances are worked out by the design engineers and are based upon the function the part is to play in the finished product and the relation of the dimensions of the part to the dimensions of the other parts with which it is used. Theoretically, the allowances established by the design engineers should be correct; but because the human element enters in here as elsewhere, they should be carefully checked by the analyst.

Close tolerances raise the cost of a machining operation by making it necessary for the operator to work accurately, checking his work frequently. More cuts are necessary if dimensions must be held accurately, and perhaps even additional operations on other machines. There is a tendency for designers to specify increasingly close tolerances, a tendency that many shopmen deplore. However, the performance requirements of many products are becoming daily more exacting, and as a result accuracy requirements are likely to become increasingly severe. Machine shops, therefore, must face this problem and learn how to work more and more accurately. That this objective can be attained is evidenced by the remarkable advances being made almost daily in the automotive and aviation industries.

When tolerances are carefully reviewed, some may be found that appear to be unnecessarily close for the function of the part hi the finished apparatus. Such cases should be presented to the engineers with a statement of the amount that may be saved by allowing greater leeway. If the tolerance really is too close and a worth-while saving will be made by increasing it, the change will in all probability be made.

It will aid materially in getting such changes made if charts showing tolerance and related cost are available for different classes of operations. Such charts serve to emphasize clearly how much costs are increased as tolerances are decreased. They can also be of value to design engineers, for reference purposes.

Occasionally, tolerances are not close enough. Sometimes, by tightening the requirements on a machining operation, the assembly is made easier, and the amount spent on the extra machine work is offset or more than offset by the saving made on the assembly floor. In standardized manufacture, fitting during assembly has been practically eliminated. Parts are machined so that they go together without filing, bending, or adjusting. The same condition is desirable in small-quantity production where much fitting is commonly done, and it can often be approached by tightening the accuracy requirements on the principal parts.

When a product is made to sell for a price, as, for example, a certain grade of shoe, the matter of allowed quality becomes extremely important. It is possible to add operations almost indefinitely that will improve quality, but the added cost will take the finished shoe out of its price range. Hence, it becomes necessary to determine what can be done for the amount of money available. In a situation of this kind, labor effectiveness is of paramount importance. The more effectively operations are performed, the more operations can be done. The more operations, the better the quality, and, hence, the better the competitive position of the shoe.


Questions - Maynard

1. If accurate work is necessary, are proper gages or other measuring instruments provided?

2. Are gages or other measuring instruments checked for accuracy from time to time?

Source: Operation Analysis, Maynard

6 Factors to Consider Before Moving to Automated Inspection
A properly programmed automatic-visual-inspection system can significantly reduce the risk of bad inspections, and lead to reduced costs over time.
Dr. Helmut Hamfeld
JUL 05, 2016
https://www.machinedesign.com/markets/manufacturing-equipment/article/21832077/6-factors-to-consider-before-moving-to-automated-inspection

https://www.automation.com/en-us/articles/2009-2/automated-inspection-gaging-systems-improve-qualit

September 15, 2019
https://metrology.news/15056-2/



LS-C-5.8 laser scanning solution for non-contact surface inspection on the machine tool.  It is  an easy-to-use, contactless solution for capturing surface measurement data quickly and directly on the production line.

New ultrasonic touch probe for fully automated thickness measurement, the RWP20.50-G-UTP, which integrates directly with a machine tool.

Measuring thickness often requires an elaborate manual setup, which includes the installation of external, manual ultrasonic measuring instruments. Hexagon’s RWP20.50-G-UTP ultrasonic touch probe automates and simplifies the procedure, as part of the machine tool installation, just like a regular touch probe.

Preventive Inspection

Shigeo Shingo highlights the concept of preventive inspection. The manufacturing process must have preventive inspection operations to prevent defects from occurring in the process of manufacturing.

The inspection occurring at the end of completion of the process may prevent the defective part from getting despatched or sent to the customer. But eliminating defects during the process has to be the first aim and it can be achieved only by inserting process defect preventing inspection operations in the process as part of process design and redesign.



Inspection Operations Industrial Engineering


Inspection operations and processes are studied and redesigned to improve productivity or reduce costs under the focus of industrial engineering: Process Industrial Engineering


________________

________________

Quality - Inspection System Industrial Engineering 


Quality system industrial engineering is the study of resource use in various quality, inspection engineering and management activities with a view to increasing the efficiency or eliminating the waste wherever possible. While the quality activities are carried out to ensure that product designs and process designs produce products and services that meet the needs of the targeted customers and delight them by giving more, there is possibility of excessive use of organization's resources. Industrial engineering is concerned with the management of resource use and in this function, the quality system design is carefully investigated by the industrial engineering to identify and remove waste. Industrial engineering succeeded in reducing the cost of many processes designed in the first iteration by the managers up to 50% and hence it is a very important activity in systems design or systems engineering.

Famous example of industrial engineering, is Henry Ford's production system redesign, that reduced the price of the automobile by half. Frederick Taylor, the founder of IE discipline has improved the productivity of some of the inspection processes.

System Industrial Engineering - System Efficiency Engineering 

Machine Effort Industrial Engineering -   Human Effort Industrial Engineering


Quality related activities are undertaken by marketing professions, product design professionals, process design professions, production persons, inspection persons in the case of products or services marketing by an organization. Apart from the various activities done by the company also need to have quality and hence all the persons in the organization are connected to quality. Statisticians contributed to quality field. Statistical quality control helped in increasing the efficiency of quality system by reducing inspection effort. Industrial engineers promoted SQC as a part of quality system industrial engineering.

To do industrial engineering of inspection methods to reduce the cost of inspection operation or cost, a redesign of the operation or process has to be done. To redesign the engineering elements, industrial engineers have to know the engineering alternatives in  terms of different inspection methods, equipment and tools like gauges etc.

In the evolving Industry 4.0 environment, inspection systems industrial engineering has to follow the applied industrial engineering steps framework created by Narayana Rao (2018).


Quality - Inspection System and Operations Industrial Engineering

Applied Industrial Engineering - Process Steps


Monitor - Explore - Analyze - Develop - Optimize - Participate - Install - Improve


Brief explanation of the Applied Industrial Engineering - Process Steps


Monitor - Technology Monitoring - Applied Industrial Engineering

Explore - Technology Exploration - Applied Industrial Engineering

Analysis - Productivity Analysis of New Technology - Applied Industrial Engineering

Develop - Develop Productivity Knowledge of New Technology - Applied Industrial Engineering

Optimize - Optimize Productivity Engineering Ideas - Applied Industrial Engineering

Participate - Participate in New Technology Implementation Projects - Applied Industrial Engineering

Install - Be An Active Member of the Project Execution and Management Team - Applied Industrial Engineering

Improve - Continuous and Periodic Improvement of Productivity - Applied Industrial Engineering



The first IE analysis of any new technology is engineering economic analysis. The investment outlay, operating cost and operating revenues are to be estimated for the new technology by industrial engineers.  Based on the estimates of these cash flows, return on investment can be calculated. If ROI is positive, industrial engineers can immediately inform management as well as their colleagues about the opportunity to adopt the new technology as early as possible to derive the benefit (ROI) from it.


Smart Inspection - Inspection Developments in Industry 4.0 Engineering/Production Environment



Smart Inspection prevents Downtime
Inspection across a production line also plays a key role in effective quality control. Our systems combine sensors like vision systems with smart data to ensure any issues have minimal impact on the line.
http://blog.omron.eu/smart-inspection-prevents-downtime/


Smart inspection solution for printed coding and marking
07 June 2019
A collaboration between SICK and AutoCoding Systems has resulted in the launch of what is believed to be the first fully-automatic smart vision inspection system for printed coding and marking on food and beverage packaging.
https://www.fponthenet.net/article/171330/Smart-inspection-solution-for-printed-coding-and-marking.aspx


2018

Inspection in the age of smart manufacturing
Written by: Tom Austin-Morgan | Published: 05 November 2018
Metrology is often an overlooked process in manufacturing, when it actually plays an essential role. In particular, inspection helps ensure that component parts fit together accurately and ensures that final products work and operate safely. Even for relatively simple manufactured products, there is more to inspection than meets the eye.
http://www.eurekamagazine.co.uk/design-engineering-features/technology/inspection-in-the-age-of-smart-manufacturing/192747/

LEAN
Applying Smart Manufacturing Technology to Conduct Smart Inspections
How a company used visual inspection software to improve its manufacturing and inspection process
PUBLISHED: THURSDAY, OCTOBER 11, 2018
https://www.qualitydigest.com/inside/lean-article/applying-smart-manufacturing-technology-conduct-smart-inspections-101118.html

Epicor Smart Inspection 2.0 Shop Workflow Solution To Be Integrated With New CarMD PRO SCAN Diagnostic Tool
Austin, Texas
October 30, 2018
Integrated solution to help automotive service businesses grow through faster, more complete vehicle inspections, diagnostics, and repairs
https://www.epicor.com/en-us/newsroom/news-releases/epicor-smart-inspection-20-shop-workflow-solution-to-be-integrated-with-new-carmd-pro-scan-diagnostic-tool/

NOVEMBER 2, 2017
Epicor Introduces ‘Smart Inspection’ Tool
Innovative mobile “Smart Inspection” tool that guides automotive service professionals through detailed vehicle inspections and generates custom-branded inspection reports that can be delivered to the customer.
https://www.tirereview.com/epicor-introduces-smart-inspection-tool/


CLEANING INSPECTIONS SIMPLIFIED
https://mysmartinspect.com/

Smart Inspection Systems
Techniques and Applications of Intelligent Vision
Book • 2003
D.T. Pham and R.J. Alcock
https://www.sciencedirect.com/book/9780125541572/smart-inspection-systems





Ultrasonic Bearing Inspection
http://www.uesystems.eu/applications/ultrasonic-bearing-mechanical-inspection/

2019
An Analysis of Modern Bridge Inspection Technologies
by SARAH MCGUIRE, ALICIA HEARNS April 29, 2019
https://www.giatecscientific.com/education/bridge-inspection-technologies/

In-Line Inspection using Combined Technologies – Magnetic ...
https://www.pipeline-conference.com/sites/default/files/papers/PTC%202009%202.2%20Beuker.pdf


 2018
What’s the optimal assembly verification method for tough inspection tasks?
Comparing traditional machine vision, human inspection, photometric, and machine learning approaches for solving the hardest inspection challenges.
Oct 1st, 2018
https://www.vision-systems.com/factory/manufacturing/article/16739326/whats-the-optimal-assembly-verification-method-for-tough-inspection-tasks


2015
Cost-effective approach to pier inspection and maintenance
Authors: G. B. Bakun,  2015
A Maintenance Management Methodology for Dealing with Marine Pier Deterioration
Preliminary Inspection - Detailed Inspection
Structural Analysis - Repair/Preventive Maintenance
Two Examples of Savings Achieved Through Analysis
https://www.icevirtuallibrary.com/doi/abs/10.1680/maosm.02739.0027

G. R. Tang and M. Jiang, "Analysis and Research on Inspection Methods of Drilling Holes in Power Transmission Line Foundation", Applied Mechanics and Materials, Vols. 799-800, pp. 1268-1271, 2015
https://www.scientific.net/AMM.799-800.1268

2013
Why New Inspection Methods Can Cost Less? - Medical device inspection
http://www.mdtmag.com/articles/2013/04/why-new-inspection-methods-can-cost-less#.UqiI-dKBni4

Method improves ultrasonic inspection of complex parts
http://www.theengineer.co.uk/channels/design-engineering/news/method-improves-ultrasonic-inspection-of-complex-parts/1016789.article

Method for optical inspection of nanoscale objects based upon analysis of their defocused images and features of its practical implementation
M.V. Ryabko, S.N. Koptyaev, A.V. Shcherbakov, A.D. Lantsov, and S.Y. Oh
Optics Express Vol. 21, Issue 21, pp. 24483-24489 (2013)
https://www.osapublishing.org/oe/abstract.cfm?uri=oe-21-21-24483

2011
The Technology of Inspection
https://www.zurich.com/NR/rdonlyres/57697FBF-094A-482B-82DC-95503C500047/0/thetechnologyofinspection.pdf

2007


APPLICATION OF EXPERIMENTAL DESIGN FOR EFFICIENT WIND TUNNEL TESTING:  THE TANDEM WING MAV CAS
By  TERESA G. ENGLISH
MS Thesis submitted to the Department of Industrial Engineering
2007
http://etd.lib.fsu.edu/theses_1/available/etd-04092007-182020/unrestricted/Manuscript_Teresa_G_English.pdf

2003
Five Steps to Cutting Inspection Costs
http://www.qualitymag.com/articles/84037


2002
Modern Methods for Quality Control and Improvement
Harrison M. Wadsworth, Kenneth S. Stephens, A. Blanton Godfrey
John Wiley & Sons, 2002 - Quality control - 683 pages

This is a revision of a classic! This text provides a single source for information on both the structure and management of quality systems and the use of statistics to control and improve quality. It incorporates an international flavor and a good balance of services and manufacturing coverage. The goal of the second edition remains the same as the first edition - to promote learning by means of practical, effective applications intended to develop, control, and improve quality systems and processes
http://books.google.co.in/books?id=PjdUqegFUewC





Poka-Yoke is a term being used to describe the devices installed in the process or operation to highlight the likely defect and prevent it.




For Zero defects, Shigeo Shingo came up with an industrial engineering solution. Industrial engineering needs efficiency sense and focus. They have to use engineering knowledge to improve the efficiency of engineering systems and reduce costs. The solution proposed by Shingo for zero defect production is Poka-Yoke. The features built into the machine and associated devices that prevent defects from happening.  The features inform the operator that a mistake has happened and provide him an opportunity to correct the mistake.

Familiar examples of Poka Yoke

1) Warning about missing attachment file you get while composing email using Gmail.

2) Websites showing password strength indicator to show password strength. So weak passwords are avoided.

3) Google search engine feature to auto-suggest spelling corrections for user search query. This helps uses to avoid making inadvertent mistakes during search.




Bibliography


‘POKA YOKE’ OR QUALITY BY MISTAKE PROOFING DESIGN AND CONSTRUCTION SYSTEMS

Iris D. Tommelein
Director, Project Production Systems Laboratory, http://p2sl.berkeley.edu/, and Professor,
Engineering and Project Management Program, Civil and Environmental Engineering Department,
215-A McLaughlin Hall, University of California, Berkeley, CA 94720-1712,

http://p2sl.berkeley.edu/wp-content/uploads/2016/04/Tommelein-2008-Poka-Yoke-or-Quality-by-Mistake-Proofing-Design-and-Construction-Systems.pdf

2008 Paper on Shingo System
http://www.cba.uri.edu/research/workingpapers/documents/2008/animplementationoftheshingosystem.pdf


Mistake-Proofing for Operators: The ZQC System

Shigeo Shingo, Productivity Press Development Team
Productivity Press, 01-Jan-1997 - Business & Economics - 80 pages


The Zero Quality Control System (ZQC) is a mistake-proofing approach that prevents defects by monitoring processing conditions at the source and correcting errors that cause defects. Since it is human nature to make mistakes, ZQC does not blame people for errors, but instead finds ways to keep errors from becoming defects. In this breakthrough approach, mistake-proofing devices called poka-yoke are used to check and give feedback about each product or operation in the process, not just a sample. This book introduces operators and assembly workers to the basic methodology of ZQC in an easy-to-read format that covers all aspects of this important manufacturing improvement strategy.

Mistake-Proofing for Operators includes the instructional features that are the signature of the Shopfloor Series. In this series Productivity Press has taken the lead in adult education by teaming with instructional designers to develop complete programs for frontline learning. The goal: to place powerful and proven improvement tools such as ZQC and mistake-proofing in the hands of your company's entire workforce.

Winner of the 1990 Shingo Prize for Excellence in Manufacturing, Mistake-Proofing for Operators is based on Zero Quality Control: Source Inspection and the Poka-Yoke System by Shigeo Shingo
http://books.google.co.in/books?id=KVQCKuhdWxgC


Poka-Yoke: Improving Product Quality by Preventing Defects
Nikkan Kogyo Shimbun, Factory Magazine
Productivity Press, 1988 - Business & Economics - 282 pages


If your goal is 100% zero defects, here is the book for you — a completely illustrated guide to poka-yoke (mistake-proofing) for supervisors and shop-floor workers. Many poka-yoke ideas come from line workers and are implemented with the help of engineering staff or tooling or machine specialists. The result is better product quality and greater participation by workers in efforts to improve your processes, your products, and your company as a whole.

The first section of the book uses a simple, illustrated format to summarize many of the concepts and main features of poka-yoke. The second section shows 240 examples of poka-yoke improvements implemented in Japanese plants.

The book:

Organizes examples according to the broad issue or problem they address.
Pinpoints how poka-yoke applies to specific devices, parts and products, categories of improvement methods, and processes.
Provides sample improvement forms for you to sketch out your own ideas.
Use Poka-yoke in study groups as a model for your improvement efforts. It may be your single most important step toward eliminating defects completely. (For an industrial engineering perspective on how source inspection and poka-yoke can work together to reduce defects to zero, see Shigeo Shingo's Zero Quality Control.)
http://books.google.co.in/books?id=hR_8Ulz6d_oC


Case Studies - Examples

Mistake Proofing, Poka-Yoke Style.
- 11/05/2018
mobile cart with poka-yoke

Five parts are to be picked on put  on the cart. The design  makes sure the associate puts the correct part on the car. This cart is wireless and speaks directly if the incorrect part is picked, or if the part is missed completely and the cart is moved.
https://www.bmwusfactory.com/team10_articles/mistake-proofing-poka-yoke-style/

https://leanfactories.com/poka-yoke-examples-error-proofing-in-manufacturing-daily-life/

https://www.rnaautomation.com/blog/poka-yoke-in-manufacturing/

https://tulip.co/blog/lean-manufacturing/poka-yoke-examples-everyday-life/

Training Programs

India
Shingo Institute of Japanese Management, Bangalore and Hyderabad
http://www.shingoinstitute.ac.in/poka-yoke.php


UK
http://www.poka-yoke.org.uk/


Incorrect statements by Quality Persons.


Juran's Quality Handbook

A few planners, managers, or engineers are planning all the steps of every process, defining carefully worded job descriptions, and enforcing the unthinking following of instructions. (P.14.7)


Manufacturing process design is not adequately described in Operations Management  textbooks. In industrial engineering books also it is not described so far.   
Developing the article: Manufacturing Process Design.
Please share useful case studies,  articles or papers. Give reference. I want to use and include in the bibliography.




Ud  22.9.2024, 22.9.2022, 22.9.2021, 28 May 2021
Pub 5 Dec 2020












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