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Quickly and easily gain insight into your production processes

• Construct personalized dashboards to monitor key indicators of manufacturing quality and performance

• Generate detailed reports in seconds instead of hours

• Manage your production line proactively, instead of reactively

• Accurately monitor production line performance, driving continuous process improvement

• Maximize yields by quickly identifying the cause of bottlenecks in manufacturing processes

Develop a deeper understanding of manufacturing processes through analysis of stored process signatures

• Quickly compare signatures from 1000’s of parts to identify features that can be correlated to product quality

• Re-analyze stored signatures to quickly optimize spec limits and test parameters

• Identify new failure mechanisms and develop new feature checks based on re-analysis of historical waveforms

• Accelerate process development, new product introduction, and line launch

• Analyze waveforms, review trends, and correlate across stations to quickly identify root causes of defects without the need for expensive and time-consuming destructive tests

Maintain 100% traceability through detailed records of end-to-end manufacturing data

• Collect and store the complete test record for every part – including process signatures—from a broad range of manufacturing hardware, including third-party tools, testers and PLCs

• Provide proof of compliance and retain detailed birth history records for regulatory requirements

Minimize the impact of quality spills and reduce warranty costs

• Quickly identify other affected parts without the need for tearing down or re-testing parts – based solely on re-analysis of stored signatures

• Confine recalls to only the defective parts

QualityWorX is the Quality Operating System that automates the collection, storage, archiving, retrieval, analysis and reporting of test

and assembly data for discrete manufacturing. It delivers unparalleled insight into critical manufacturing processes, providing the

competitive edge demanded by today’s manufacturers. From the plant floor, to the engineering labs, to management offices around

the globe, QualityWorX delivers the visibility manufacturers need to meet their production goals of improving both quality and yield

while reducing costs.

FEATURES & BENEFITS

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FUNCTIONAL OVERVIEW

Remote Office

EthernetSwitch

WebServer

MES or ERP

PlantFloor PC

sigPOD

sigPOD

PLC

Third ParyTester

sigPODGateway

EthernetSwitch

Remote Office

Reporting Tools

Central Database

Engineering Workstation Analyst

QualityWorX is a suite of software tools that automates the collection, storage, analysis, and reporting of manufacturing data. It

combines the flexibility and speed of a SQL database, the power of advanced analytics, and the ease and accessibility of web-based

reporting. All types of production data, including assembly, test, and repair operations, are collected from a wide range of plant

floor systems for storage within the QualityWorX database. Reporting and analysis tools access the database across local and wide

area networks, providing critical insight into the manufacturing processes and production line performance to all levels within the

manufacturing organization.

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COMPONENTS OF QUALITYWORX

SUPPORTED DATA CONNECTORSSigPOD Automatic connection to sigPOD units

OPC Connects OPC server to device (e.g. PLC)

Rundown Tools

Atlas-Copco PowerMACS, PowerFocus

Bosch Rexroth Tightening Systems

Data Connectors

XML QualityWorX XML format

Serial Multiple ports (real + virtual), handshaking supported: OPC, DI/DO

FTP Client sends data to FTP server, XML file format

PLC Data transmission using OPC server (e.g. Kepware) or fieldbus via sigPOD or Gateway – PROFINET, EtherNet/IP, Modbus TCP,

PROFIBUS, DeviceNet

Insertion API Proprietary API allows 3rd party software applications to push data directly into QualityWorX

SQL DATABASEAt the core of every QualityWorX installation is a SQL database

built on Microsoft SQL Server technology. Architected to

efficiently store and organize all of your production data,

including process signatures, features, spec limits, part-specific

parameters, and defect and repair data. Management tools facilitate the configuration of the database structure and the regular,

automated archiving of stored data.

The database is designed to grow with your testing and manufacturing needs. Multiple QualityWorX Data Servers can run at the same

time. Automated utilities gather old history data in secure archives, without any interruption in production. This ensures speedy access to

the latest production data while still allowing for full analysis of all current and archived data.

INTEGRATE SEAMLESSLY WITH PLANT NETWORKSAdd QualityWorX to your plant network and quickly begin collecting and analyzing data from the entire family of sigPOD test stations.

Proprietary connections can be enabled to pull data from fastening and rundown tools including Atlas Copco, Bosch, and others.

Open standards such as XML and OPC ensure that 3rd party devices are also able to leverage the storage and analysis power of the

QualityWorX suite.

During production, new models and parts can be configured on the fly, and test stations can be added or deactivated in QualityWorX

without any production downtime.

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The Web Reporter is the standard reporting interface for QualityWorX, and a site license is provided with every database installation. The

Web Reporter combines a simple, but powerful web-based interface with a comprehensive library of standard reports to enable all levels

within the manufacturing organization to quickly retrieve, analyze and summarize production data.

ACCESSIBLE TO ANYONE, ANYWHERE • Web-based application provides complete access to quality data from any computer

with a network connection

• Simple, intuitive interface makes it accessible to all levels within the organization,

from technician to manager

• No local software to install, all you need is your web browser – simply install the

application on your web server, configure and go!

COMPREHENSIVE LIBRARY OF POWERFUL REPORTS• Quickly and accurately calculate First Time Yield, and identify

top failure categories

• Generate detailed summaries of product quality, performance

and yield using one of eight powerful, configurable reports

• Precisely define desired dataset using flexible, powerful query

builder

• Export any report to PDF or Microsoft Excel native format, or

generate printer friendly versions for printing directly from

your browser

• Click on a serial number in any report to drill into its detailed

birth history record

• Report tables feature drill-downs or collapsible tables to

expose as much, or as little detail as desired

STANDARD REPORTS1. Part History

2. First Time Yield

3. Summary Report

4. Trend Browser

1 2

3

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Create a Report in 4 Steps1. Enter query parameters.

2. Click button to select report.

3. Fill in report options.

4. Launch report.

5. Failure Report

6. Failure Pareto

7. Repair Traffic

8. Defect Pareto

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First Time Yield

Trend Browser

Summary Report

STANDARD REPORTS IN WEB REPORTER

Part History

Intuitive tree-based navigation of birth history data enables detailed investigation of

pass/fail results, waveform characteristics and feature checks on a single serial number.

First Time Yield

Calculate First Time Yield (FTY) by station or Rolled Throughput Yield (RTY) across

multiple stations.

• Toggle chart between FTY vs. station, and RTY vs. time, where RTY is calculated over

a period of a day, week, or month, as selected by the user.

• First Time Yield is the number of unique parts without any failures (at that station),

divided by the total number of unique parts through the same station.

• Rolled Throughput Yield is the product of the individual station FTY values.

Summary Report

Generate a detailed summary table of operation yields, or click on an operation to bring

up a detailed table of feature statistics. User selects from a list of 13 statistical parameters

that can be incorporated in the feature table, as well as embedded charts that provide

quick, at-a-glance displays of feature trends.

Trend Browser

Drill down to individual operations or features and display trend chart vs. serial number

or date-time stamp. Toggle between detailed serial number list, and yield and statistical

summary.

Failure Pareto

Quickly generate a Pareto chart of the top 10 failures. Drill down to a list of affected

serial numbers, then link to individual part history report to quickly isolate and identify

production issues.

Failure Report

Review detailed listing of failed serial numbers with breakdown of individual failures by

station and operation.

Defect Pareto

Create Pareto chart of top 10 defects, categorized by defect or repair details. Drill-downs

and links to individual serial numbers assist in rapid identification of primary sources of

defects (only available if Sciemetric Repair Bay Manager installed on production line).

Repair Traffic

Detailed list of all serial numbers that have been repaired, specifying both the defects and

the repairs (only available if Sciemetric Repair Bay Manager installed on production line)

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The QualityWorX Dashboard provides a unified reporting environment

that supports three distinct levels of reporting, each providing

progressively higher levels of detail. First, the Dashboard tab provides

high level, at-a-glance summaries of key manufacturing metrics.

Clicking on a dashboard report brings up the corresponding Report

page, which combines tables and charts to provide the next level of

detail. The Reports and Part History can also be accessed by selecting the

corresponding tab, then applying the desired the database filters and

report options. Report configurations can be saved and then launched

directly from the Report Manager, allowing you to quickly generate commonly used reports without having to re-enter query parameters.

The layout of the Dashboard web page is shown in the figure above. Navigation between the three reporting levels is performed by selecting

the appropriate tab at the top of the main panel. Other functions, such as the Report Manager or Preferences, are accessed from the toolbar

anchored to the left of the main panel. File management buttons are grouped in a second toolbar at the bottom of the main panel.

The Dashboard offers three categories of reports: Dashboards, Standard Reports, and Part History.

The following chart types are supported in the Dashboard library:

Needle Gauge

CHART TYPE CHART FEATURES CHART OPTIONS SIZING OPTIONS

Pie Chart

Line Chart

Bar Chart

• Numerical value prominently displayed at bottom of gauge

• Red, Yellow, Green zones for rapid visualization

• Text labels indicate numerical breakdowns

• Shading (select reports) provides visual emphasis of upward or downward trends

• Below target values highlighted in red – above target in green

• Limit the number of bars displayed to prevent overcrowded reports

• Sort columns in ascending or descending order

• Small, medium, large diameter• Font size: small, medium, large

• Small, medium, large diameter• Font size: 8, 10, 12, 14, 16,

18, 20 point

• Small, medium and large size• Aspect ratio: 1, 1.5 and 2• Font size: 8, 10, 12, 14, 16, 18, 20

point

• Small, medium and large size• Aspect ratio: 1, 1.5 and 2• Font size: 8, 10, 12, 14, 16, 18, 20

point

• Upper/Lower bound of gauge range• Minimum (upper bound of Red range)• Target (upper bound of yellow range)

• Target value – displayed as solid green line

• Target value – displayed as solid green line

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DASHBOARDSThe Dashboard tab provides a user-configurable environment for creating concise, at-a-glance summaries of key performance indicators.

Configuration options include:

• Create sub-tabs to organize your reports. Re-position reports within the tab simply by dragging and dropping

• Dashboard configurations are saved automatically with every change. Export configuration files to your local computer and share with

other users

• Configure sizes of charts, and choose font sizes to suit your display

• Each report offers a variety of configuration options that enable you to tailor each instance to address a specific metric

In addition, the Dashboard offers the following powerful features:

• Most Dashboard reports feature click-throughs that automatically bring up detailed reports on the same dataset, allowing the user to

drill down from high level summary to low level detail in just a few clicks. For example:

- Click on a bar in an FTY Trend to generate a Failure Pareto report for the dataset associated with the specific FTY bar, then drill down to a

serial number and open its part history report to review its waveforms.

- Open a part count report that features dynamically adjustable binning by clicking on a Part Count gauge or trend chart.

• “Marquee view” – this option allows the administrator to configure a live dashboard that is automatically updated based on a

configurable timer. Designed for use as a public display board, whether on the plant floor or in the office, the Marquee view features a

narrower top banner and removes the toolbar to maximize the available display area. Accessible only with an Administrator login.

The current library of dashboard reports includes the following report definitions:

Failure Pareto

Feature Trend

First Time Yield Gauge

First Time Yield Trend

Parts Count Trend

Parts Count Gauge

Operation Gauge

REPORT DESCRIPTION CHART TYPE CHART FEATURES AND OPTION

• Bar chart• Pie chart• Line chart

• Needle gauge

• Line chart (shaded)

• Bar chart• Line chart• Bar chart

• Line chart (shaded)

• Bar chart

• Pie chart

Display top failures by station or operation

Drill down to a specific feature on any station, operation, or waveform, and plot vs. time or serial number

Display FTY across a selection of sections and stations

Trend FTY vs. time or compare FTY by model, section, station or part parameter

Trend parts count over time or compare by model, section, station, or part parameter. Use the op count filter (first, last, >, ,

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ANALYSIS GRID

Flexible spreadsheet-like table allows engineers to create custom analysis and charts. Add columns with mathematical formulas, sort, apply filters

or aggregate data (sum, average, minimum, maximum). Export your charts to a Dashboard panel with a few clicks.

REPORTS

The Dashboard includes all of the standard reports offered in the Web Reporter,

including the Part History report. While maintaining the same general interface and

layout, the Dashboard adds a number of powerful and convenient features:

• The user can save and load report configurations to quickly generate

frequently used reports.

• Configuration files can be exported or imported to/from the desktop so that

they can be shared with colleagues.

• Account-specific preferences allow the user to choose default settings for

each report type.

• Click-throughs on select reports enable rapid drill-downs

In addition, the new Analysis Grid custom analysis tool has been added to complement the original eight reports.

Operation Trend

SPC Trend Chart

Feature Comparison

Feature Gauge

• Line Chart

• Line Chart• Bar Chart

• Bar chart

• Needle gauge

Plot operation result vs. time to reveal if there are any unusual trends in the pass/fail results

Drill down to a feature and trend Avg, Min, Max, Sum or Std Dev vs. time, grouping by time-date or by number of records (eg: every 10 data points), or plot vs. model or part

Compare Avg, Min, Max, Sum or Std Dev between multiple features, across sections, stations, operations and waveforms

Track a feature value in a gauge, selecting from Avg, Min, Max, Sum or Std Dev.

• Aggregate by Avg, Min, Max, Sum, Std Dev, • Bin time by shift, hour, day, or week• If the same feature label appears in multiple

stations, compare sections, stations

• Limit number of bins and sort in ascending or descending order

• Aggregate by Avg, Min, Max, Sum, Std Dev

REPORT DESCRIPTION CHART TYPE CHART FEATURES AND OPTION

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PRODUCTIVITY TOOLS

The Dashboard features a set of productivity tools that help accelerate report generation through personalization,

file management and information displays. In addition, administrators can tailor access to specific functionality

through a simple user rights management interface.

REPORT MANAGER

The Report Manager provides a convenient utility for managing stored definition files created in the Reports or Dashboard tabs:

• load a stored report configuration into the “Reports” tab, ready to be edited

and launched

• delete or rename report files

• Import or export files from the server directory to a local directory to enable

you to share files with other users

• launch reports directly from the Report Manager file list

PREFERENCES

Each user can set their own personal preferences to help facilitate rapid report

generation. Available preferences include default settings for all of the Reports and

many of the Dashboards.

ADMIN TOOLS

The Admin Tools tab contains configuration and administration settings that are

only available to logins that have administrator privileges. Within this section,

there are three divisions, each organized into its own tab:

1. Connection Manager: allows the administrator to edit or delete existing

production line definitions, or configure new ones

2. Rights Management: contains User Rights Management settings, where access

to reports, features and tools can be enabled or disabled based on user groups

3. Admin Password: Provides management of the Dashboard administrator’s password, which is used to gain access to the Admin Tools

from the login prompt

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For advanced data analysis, the Engineering Workstation features a powerful mathematical

processing engine that can simultaneously analyze thousands of waveforms, rapidly

simulate a broad range of test scenarios using historical data, or identify defects using

line-wide trends and correlations. These advanced capabilities are combined with a suite

of standard reports to provide the ultimate in data analysis and reporting environments. Engineering Workstation is ideally suited

for Manufacturing and Quality Engineers who are tasked with developing and implementing new production processes, maximizing

production yields, optimizing throughput, and identifying root causes.

DATA ANALYSIS The Data Analysis function is a sequence editor that applies a series of functional steps to a dataset. A dataset consists of process

signatures and/or scalar data points for a specified subset of parts. Feature values can be extracted from the waveform data

by applying sequences of signal processing steps and signature analysis algorithms. Limits can be applied to feature values,

and optimized to ensure accurate separation of good and bad parts. This allows areas of interest to be isolated, compared and

manipulated, leading to the identification of manufacturing anomalies, which can then be eliminated by fine tuning the appropriate

process control limits.

Waveform Processing Functions

ClipperConcatenateDerivativeExtract WaveformFFTHigh, Low or BandpassIntegralKernelLinear FilterMax TrackMin Track

Waveform Feature Types

AreaCuspEnvelope WindowGet Y at XKneeKurtosisMaximumMeanMedianMinimumNumber of Points

Sequence Editor Functions

Data and Waveform Calculate Apply Signature Analysis function Apply Process Data functionLimit Check Conditionals and Loops: If, Else, While

Moving Window RMSNotch FilterPop Noise FilterRemove DCSmootherSynchronous Filters

Peak to PeakPower SumRise/Fall TimeRMSSkewSlopeStandard DeviationThreshold CountThreshold CrossingVariance

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STANDARD REPORTS IN ENGINEERING WORKSTATION ANALYSTIn addition to the powerful analysis tools described above, the Engineering Workstation also comes

with seven standard reports. The majority are shared with the Web Reporter and are described in

detail in the Web Reporter section. The Real-Time Status report is unique to Engineering Workstation,

and the Trend Browser offers a number of additional features not present in the Web Reporter

or Dashboard.

Trend Browser

A more powerful version of the Trend Browser in the Web Reporter and Dashboard, it offers the

following additional features:

• Overlay multiple waveforms on common axes to spot variations over multiple test stations and parts

• Highlight an individual trace by clicking on the serial number in the legend

• Overlay control limit waveforms (e.g. 3-sigma envelope)

• Zoom / pan / isolate and highlight data points

• Plot feature data as a histogram / R-chart / X-Bar / line chart

• Identify serial number by clicking on a data point on the graph

Standard Reports

1. Part History

2. Trend Browser

3. Failure Report

4. Failure Pareto

5. Repair Traffic

6. Defect Pareto

7. Real-Time Status

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2

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1

This example shows process signatures from 1000 parts captured at the same test station. 4 types of signature groupings can be easily seen.

1. Compliant: Well-behaved signatures, tightly grouped and exhibiting expected characteristics.

2. Not compliant: These signatures clearly deviate from expected behaviour. Easily detected by most test systems.

3. Not compliant: In this case these are true failures that exhibit some of the desired behaviors, but still deviate from the norm. Easy to detect with process signature technology, but more difficult to catch with classical systems.

4. Almost compliant but still failures: Subtle deviations from “normal behaviour” that would pass most tests and are only clearly visible in process signatures analyzed by QualityWorX.

Real Time Status

The Real Time Status is automatically updated at a user-controllable rate to provide real-time production trends. The Real Time Status

report takes a snapshot of information in the QualityWorX database according to user-specified criteria.

• View real-time data on part pass/fail, timestamp

• Select a live part to see its part history

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OPTIONAL COMPONENTS

DATABASE MANAGEMENT TOOLS

ERP BRIDGE Add the MES / ERP Bridge option to the QualityWorX network to

provide:

• Configurable, secure access to scalar data contained within the

QualityWorX Data Server

• Flat table structure that dramatically simplifies access to database

fields

• Exposure of live part information such as status, test results and

build codes

• Data transfer simplified using auto store and removal functions

REPAIR BAY MANAGER Add the Repair Bay Manager module to the QualityWorX network

to provide defect and repair management:

• Guides operators through repair process with complete access to part

history record

• Suggested repair function (based on defect type)

• Stores all defect and repair information in QualityWorX database as

part of birth history record, including location, component, defect

type and repair type

• Provides both manual and automatic interface to the production

line for entry and release from repair station

• Runs as a separate application on a sigPOD 1010 Data Node or any

PC running Windows XP Pro, with a connection to the QualityWorX

database

The database management tools are included with every database license. These tools are typically used by the database administrators

to configure the production lines within the database, and manage the archiving of data from active databases.

ARCHIVE TOOL The Archive Manager is used to manage the data stored within the database, by allowing the database administrator to copy, move

or delete records. Archive jobs can be created, saved and executed from the Archive Manager interface, or can be scheduled to run at

regular intervals using the Windows Scheduler utility.

CONFIGURATION TOOL The Configuration Tool is a utility that allows the system administrator to configure production lines in the database. This includes

defining all the part types, sections, and stations, as well as the relative order of the stations in the line. It is also used to deactivate stations

or serial numbers. All production line database users and passwords are managed with the Configuration Tool.

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PRODUCT CONFIGURATIONS

DATABASE CONFIGURATIONS

• QualityWorX® Base Five (5) connection database license for installation on a

customer provided Microsoft® SQL Server 2005 or 2008 R2

running on a 32 or 64-bit MS Windows® OS. Includes one

(1) unidirectional connector and Web Reporter site license.

• QualityWorX® Enterprise Unlimited1 connection database license for installation on

a customer provided Microsoft® SQL Server 2005 or 2008

running on a 32 or 64-bit MS Windows® OS. Includes Web

Reporter site license.

• QualityWorX® Enterprise Secondary2 Unlimited1 connection database license for installation

on a customer provided Microsoft® SQL Server 2005

running on a 32-bit MS Windows® OS. Licensed for use on

a Primary database feeder line.

• Engineering Workstation Analyst Single License One (1) concurrent license to connect to a QualityWorX

Database and all Secondary databases on same Product Line.

• Engineering Workstation Analyst Site License Unlimited concurrent licenses to connect to a

QualityWorX Database and all Secondary databases on

same Product Line.

• QualityWorX® Enterprise Bundle Unlimited1 connection database license for installation on

a customer provided server Microsoft® SQL Server 2005

or 2008 R2 running on a 32 or 64-bit MS Windows® OS.

Includes Dashboard site license.

• QualityWorX® Dashboard Site License Advanced web-based reporting tool for QualityWorX.

License allows for unlimited client connections and an

unlimited number of separate QualityWorX database

connections. Provides a single instance of the web server

application only. Maintenance, installation and training

charged separately.

1 Total number of connections limited by server capacity and configuration.

2 A secondary database is required for each feeder line associated with the primary assembly line (e.g., head assembly, head machining, block machining etc.). One secondary database can support multiple, identical lines (e.g. three head assembly).

HARDWARE PACKAGE

• Model 1010 SigPOD Data Node Platform

• Runs data connector applications to connect 3rd party

hardware to QualityWorX server

• Compact form factor and Industrialized packaging for flexible

placement on the plant floor

• Supports up to 10 connections to a QualityWorX server

• Includes Windows XP Pro, CPU, DVD-R/W drive

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www.sciemetric.cominquiries@sciemetric.com1-877-931-9200© 2013 Sciemetric Instruments, Inc. All brand and product names are trademarks or registered trademarks of their respective companies. Products and specifications subject to change without notice.

Rev 5, May 2013

Min 2.4 GHz Pentium dual-core processor or equivalentXeon 3.0 GHz processor recommended

4 GB min

80 GB free hard disk space min, not including size of customer data, which depends on application.Database drive should be RAID 1 configured for data backup.Note that database performance is dependent on drive seek/access times.

CD-ROM, Backup system (DVD/DVD RAM/Tape): Tape backup is highly recommended

SVGA (800x600)

Microsoft Windows Server 2003 or Microsoft Windows Server 2008 – 64 bit

Microsoft SQL 2005 Standard Edition, or SQL 2008

Ethernet 100 Base T connection

QualityWorX Data ServerSQL database and associated management tools

QualityWorX Web Reporter ServerOR Dashboard Server

QualityWorX Engineering Workstation Archive ToolConfig ToolAdvanced desktop analysis and reporting software

Min 1 GHz Pentium dual-core processor or equivalentXeon 3.0 GHz processor recommended

4 GB min

1 GB of free hard disk space min

CD-ROM

SVGA (800x600)

Microsoft Windows Server 2003 or Microsoft Windows Server 2008 – 64 bit(Recommended)

Microsoft Internet Information Server (IIS) Microsoft .NET Framework 2.0 (or later)

Ethernet 100 Base T connection

Pentium® 4 (or equivalent), 1.8 GHz or higher

1 GB min

2 GB of free hard disk space min

CD-ROM

XGA (1024x768)

Microsoft Windows XP Pro, min SP2

–

Ethernet 100 Base T connection

PROCESSOR

MEMORY

HARD DRIVE

REMOVABLE DRIVE

DISPLAY

OPERATING SYSTEM

ADDITIONAL SOFTWARE

CONNECTIVITY

HARDWARE INSTALLATION REQUIREMENTS

Web-based reporting application