Automated quality control: implementation and digitalization in home product manufacturing lines

This study, conducted at Procter & Gamble's Quality Assurance department in Germany, explores the practical implementation of automated quality control in a home product manufacturing line for Swiffer Duster. Line 47, characterized by its contemporary and intricate design, presents unique challenges in streamlining and automating quality control processes. The primary objective is to identify and incorporate critical consumer quality parameters (CCQPs) into the production process to enhance product quality and operational efficiency. Part I: Understanding and Defining Quality: The research begins with an in-depth examination of Line 47, involving close collaboration with operators and engineers to identify persistent challenges. Through a partnership with the Research and Development team, the study focuses on analyzing consumer complaints to pinpoint eight critical parameters, referred to as Primary Quality Factors, essential for maintaining high-quality standards in the finished products. Part II: Implementation of Sensors and Data Collection: The second phase involves the integration of digital technologies to monitor these Primary Quality Factors. Sensors were strategically installed to measure key parameters, from wax levels to product stacking height. Careful calibration and signal response analyses ensured that data collection was both stable and reliable, laying the foundation for real-time quality monitoring. Part III: Validation and Verification of Primary Quality Factors: The final phase of the research focused on validating and verifying the identified quality factors. Systematic tests varied each parameter to ensure operations remained within the validated range. Over a two-month verification period, finished product characteristics were monitored hourly, and statistical analyses confirmed the reliability of the parameters. These quality factors were then integrated into the production system with real-time visibility and interlocks, ensuring continuous adherence to quality standards. This research demonstrates the effective integration of advanced technology into manufacturing processes, showcasing the tangible benefits of automated quality control in the production of home products. The findings highlight the potential for improved product quality and operational efficiency through the systematic application of Quality by Design principles.