Root cause a bad batch from its parameters
When something does not form, the pressure, temperature and speed it ran at are already recorded against the job. The investigation starts with facts rather than theories.
By job role
Every batch, with the conditions it was made in.
Quality investigations usually begin with people trying to remember. Output IQ records pressure, temperature, speed and the rest continuously, so the conditions a batch ran in are already on file before anyone asks.
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Live conditionsLive
PRESS-04 pressure
Against set point
138
Set point100%↑ 38.0% Upper limit115%↑ 20.0%
Out of range
This batch
11
Prev batch2 min↑ 450% Batch average4 min↑ 175%
Parameters logged
Continuously
32
With limits26↑ 23.1% Alerting18↑ 77.8%
The problem
The record gets written after the event, by somebody who was busy.
Paper checks are a snapshot taken when someone had a minute. What happened between those snapshots is the part that usually caused the problem, and it is the part nobody has.
01
A complaint becomes an argument
Without the conditions the batch ran in, a customer claim comes down to two opinions. That is an expensive way to settle something that a recording would answer in a minute.
02
Out of spec is found at inspection
By the time a check catches a drift, the parts are made. Knowing at the machine that pressure has climbed is worth more than knowing at the end that it did.
03
Traceability means reconstructing it later
An audit asks how a batch was made and the answer is assembled from sheets, memory and a spreadsheet. It is slow, and it is only as good as the recording that never happened.
What you get
Evidence for every batch, not assumptions.
Record key parameters live, no paperwork
The machine reports its own conditions continuously. No hourly check sheet, no transcription, and no gaps between one reading and the next.
Investigate complaints on data, not guesses
A customer reference goes back to a job, a machine, a shift and the exact conditions it ran in. You can answer with a record rather than a promise to look into it.
Get alerted the moment a parameter drifts
Limits you set, watched continuously, with the alert going out as they are crossed. That is the difference between scrapping a batch and stopping one.
Evidence for ISO 14001 and ESG reporting
Consumption and conditions recorded as they happen, by machine and by site. The evidence an audit or a customer questionnaire asks for already exists.
Where the numbers come from
Four sources, one figure.
None of this is typed in by anybody. The number you look at is assembled from the parts of the business that already produce it.
The ERP
Orders, stock, purchasing and finance. What was sold, what it was quoted at and what was bought to make it.
Mobile job tracking
Jobs booked on and off from a phone or a tablet on the floor. Labour lands against the job as it happens, not on a timesheet at the end of the week.
Connected sensors
Power, vibration, heat, pressure and run hours, straight off the machine. Nothing to key in and nothing to remember.
A record nobody had to write
Conditions logged continuously against the job, the machine and the shift. Traceable in both directions, from batch to conditions and from a reading back to what it made.
Out of range, this batch 11 Pressure above set point, timestamped
In practice
Measured, anonymised results will be published here as our first deployments report them. Nothing invented goes on this page in the meantime.
The rest of the business
The same feed, read a different way.
Questions
The ones quality managers ask.
How often are readings taken?
Continuously rather than on a check interval, so drift shows as it happens rather than at the next inspection.
Can I tie a reading to a specific batch?
Yes. Readings attach to the job running on that machine at that time, so a batch reference resolves to conditions and back again.
Will this satisfy an auditor?
It gives you a recorded, timestamped source rather than a reconstructed one. What an auditor accepts is their call, but the evidence is stronger than a check sheet.
What if a parameter we care about is not covered?
Tell us what it is. The sensor range grows, and we will say plainly whether we can measure it rather than promising and finding out later.
Does this replace our quality system?
It feeds one. What it adds is the continuous condition record underneath the checks you already do.
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