SPC (Padmavati)
Paper-based quality checks caused delayed fault detection and high rejection/rework rates. Digital air-gauge integration with Velonex now automates SPC, Cp/Cpk monitoring, and instant deviation alerts.
Problem Statement
Critical manufacturing parameters were monitored by the client using paper-based quality records and manual measurements. As a result, there was less process visibility, inconsistent data collection, delayed fault identification, and a greater reliance on manual inspections. Higher rejection rates, rework, and decreased production efficiency resulted from the inability to detect process deviations early due to a lack of real-time process monitoring.
Solution
Velodynamics automated statistical process control and quality data gathering by integrating the Velonex SPC Module with digital air gages. The air gages directly record critical dimensions, which are then instantly sent to the Velonex platform. SPC analysis, process capability (Cp/Cpk) monitoring, control chart generation, process deviation detection, and immediate notifications via an interactive dashboard are all automatically carried out by the system. This makes it possible for operators and quality teams to maintain consistent product quality and make data-driven decisions.
Functionalities
Digital Air Gauge Integration
Digital Air Gauge Integration for automatic measurement data capture
Real-Time SPC Monitoring
Real-Time SPC Monitoring of critical quality parameters.
Automatic Data Acquisition
Automatic Data Acquisition without manual data entry.
Process Capability Analysis
Process Capability Analysis (Cp, Cpk, Pp, Ppk).
Real-Time Process Deviation Detection
Real-Time Process Deviation Detection with instant alerts
Out-of-Control Condition Detection
Out-of-Control Condition Detection using SPC rules (Western Electric/Nelson Rules).
Live Quality Dashboard
Live Quality Dashboard with machine-wise and line-wise monitoring.
Trend Analysis
Trend Analysis for continuous process improvement.
Tolerance Limit Monitoring
Tolerance Limit Monitoring (USL/LSL).
Gauge Health & Calibration Tracking.
Tech Stack
Layer
Technology Stack
Frontend
Angular
Backend
.Net core 8
Database
MSSQL
Cloud & Hosting
Amazon Web Service
Notifications & Services
Firebase Cloud Messaging (Mobile Application) / MessageHUB / SignalR
Impact on Client
Eliminated manual quality data entry through direct digital integration.
Improved accuracy and reliability of inspection data.
Enabled real-time monitoring of critical process parameters.
Reduced inspection time and operator effort.
Early detection of process variations, minimizing defects and rework.
Improved process capability through continuous SPC monitoring.
Increased production efficiency and reduced quality-related downtime.
Enhanced traceability with centralized digital records.
Improved compliance with quality management standards.
Enabled data-driven quality improvement and continuous process optimization.
Testimonials
"Velonex by Velodynamics has driven a major transformation in our manufacturing operations. Velodynamics stands out for their deep understanding of our unique production challenges and their ability to engineer a custom IoT solution that fits our workflow perfectly. Their commitment to personalized, high-performance software makes them a trusted partner in our growth."
Santaji Mane
R&D Head
ZP
August 2022
“The Data Monitoring Dashboard has transformed how we manage our casting line at Saroj. Having real-time visibility into multi-parameter machine data right at our desks allows us to spot process variations early and keep the line running smoothly without unexpected disruptions. The automated weekly reports and intuitive visual charts have made shift tracking far simpler for my team, leading to a noticeable boost in overall shop floor efficiency.”
Santaji Mane
Development Head
ZP
November 2022
