For many manufacturers, ensuring product quality is a constant battle against waste, rework, and inefficiencies. In this illustrative example based on real industry challenges, a manufacturer in the electronics sector faced significant expenses due to high scrap rates and costly rework. Their reliance on human inspectors for visual quality checks led to inconsistent results, making it difficult to maintain high standards while keeping costs down.
The Quality Assurance (QA) team believed a camera inspection system could solve this problem by improving accuracy and reducing defects. But leadership wasn’t convinced. The team needed clear, data-driven evidence to prove that investing in automation would lead to measurable improvements in quality and cost savings. The results from the new system would include more accurate information about whether the unit being tested was defective or non-defective.
To determine whether camera inspections were truly more effective than human inspectors, the QA team turned to Minitab Statistical Software. They conducted a Gage R&R study to measure the variation in inspection results and an Analysis of Variance (ANOVA) to compare performance between human inspectors and the camera system.
The results were telling: the camera system delivered more consistent, reliable inspections while human error introduced variability that led to unnecessary waste. On paper, the findings were compelling. However, presenting raw statistical analysis to executives was another challenge—one that required a more strategic approach to data visualization and communication.
This is where Minitab Dashboards played a critical role. Rather than sharing spreadsheets filled with numbers, the QA team compiled their findings into a clear, interactive dashboard that made the case for automation undeniable.
By translating complex statistical findings into a visual story, the team made it easy for leadership to see the true impact of camera inspections determining whether each tested unit is defective or non-defective. As a result, leadership approved the investment, leading to improved quality, lower costs, and a more efficient production process.
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Implementing camera inspections was just the beginning. With Minitab Dashboards, the company continued tracking quality metrics, allowing them to monitor trends, identify new opportunities for improvement, and ensure their investment continued delivering value. They even expanded their camera inspection strategy to suppliers, ensuring consistent quality throughout their supply chain. This example illustrates how Minitab Dashboards transform statistical analysis into actionable insights, making data-driven decisions more accessible and effective across all levels of an organization. |
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For manufacturers and quality teams looking to justify investments, optimize processes, or gain visibility into performance, Minitab Dashboards provide the clarity and confidence needed to take action. See for yourself how Minitab can help you turn raw data into powerful, strategic insights.