Real-Time Quality Control Software for Precision Manufacturing
Elevate Quality Control in Steel, Aerospace, and Automotive Manufacturing by harnessing MERLIN Tempus for real-time insights, predictive analytics, and unparalleled product quality.
“Quality issues aren’t just expensive — they’re preventable.”
The Hidden Costs of Overlooking Quality
In manufacturing, what you can’t see can absolutely hurt you. Minor stoppages, inconsistencies, and undetected defects seem harmless on their own, but they accumulate into thousands of lost production hours every year.
Manufacturers lose up to 36 hours a month to micro-stoppages. These hidden inefficiencies cost companies thousands of dollars monthly and can lead to customer dissatisfaction and product recalls. As Industry 4.0 reshapes the factory floor, manual inspection and reactive maintenance are no longer sufficient.
It’s time to elevate the modern manufacturing floor with intelligent quality control strategies that can be embedded in your everyday operations. To do this, manufacturers need a method to track scrap passively and be able to classify their rejected parts on the fly. In the age of IIoT and intelligent manufacturing, software solutions exist that can do most- if not all of the heavy lifting for you, offering comprehensive machine monitoring and reject tracking every second of every day.
MERLIN Tempus – Quality Control Built Into Every Second
Imagine a production floor where defects are caught at the source, not downstream. Where machines signal anomalies, and predictive analytics alert your team before a quality slip becomes a shipment delay. Machine monitoring and quality control software solutions, like MERLIN Tempus, make this possible.
MERLIN Tempus captures real-time data, tracks scrap parts, classifies rejects, and triggers alerts based on your rules. Micro-stoppages, once invisible, are surfaced and corrected. With MERLIN, quality control becomes a living, breathing part of your operation, empowering your teams and protecting your output. Comprehensive reject tracking with both machine and operator input comes right out of the box with MERLIN Tempus.
Real-World Success: Quality Control Software in Action
Mazak Corporation: Real-Time Visibility for Higher Quality
At Mazak, the deployment of MERLIN enabled real-time machine monitoring, revealing hidden inefficiencies impacting production quality. By addressing unplanned downtime and micro-stoppages, Mazak significantly improved Overall Equipment Effectiveness (OEE), directly enhancing product consistency and quality. Their commitment to real-time data dramatically reduced defect rates while boosting throughput.
Rose Integration: Transforming Quality Through Data Transparency
Rose Integration leveraged MERLIN to elevate its OEE from 40% to 82% in just 18 months. Through real-time reject tracking and operator accountability tools, quality deviations were caught earlier, minimizing rework and scrap. This transformation not only streamlined production but embedded a culture of continuous quality improvement on the factory floor.
Ford Motor Company (Mexico): Reducing Quality Risks with Better Data Control
Ford’s adoption of Memex solutions addressed critical issues of data starvation in CNC machines, which previously led to process inconsistencies. By ensuring uninterrupted access to part programs and machine data, Ford significantly improved machining quality and reduced defect rates, while also increasing machine feed rates by up to 150%.
Why Quality Must Evolve With Your Industry
Steel service centers, aerospace firms, and automotive producers each face unique pressures. Whether ensuring traceability, achieving regulatory compliance, or minimizing mass production errors, MERLIN Tempus adapts to your specific needs with predictive analytics and real-time quality control and monitoring built-in.
- 1 in 3 manufacturers cite data delays as a reason for missed defects.
- Micro-stops and unplanned downtime cause thousands of hidden scrap hours per year.
- Manual inspection can’t scale — your machines already know what’s wrong. MERLIN just listens.
Smarter Infrastructure, Smarter Choices
Today, manufacturers must weigh the true cost of SaaS dependency versus owning their industrial data. As Memex notes: “The illusion of security in cloud-only monitoring shatters when breaches occur.” Read more here.
With MERLIN, manufacturers can retain control with either on-premises or hybrid deployments. The perpetual licensing model ensures lower long-term costs and better security compared to endless SaaS subscriptions.
Learn more about MERLIN’s various deployment options by contacting our sales team.
Ready to Experience Quality Control at Full Power?
No more guessing. MERLIN Tempus helps every machine and process actively drive quality excellence. Book a demo, get a QC dashboard preview, and start seeing immediate improvements.
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Frequently Asked Questions About Quality Control in Manufacturing
What is real-time quality control?
Real-time quality control involves monitoring production data continuously to track scrap, classify, and address defects immediately, reducing waste and improving product consistency. This is the essence of quality control software.
How does predictive analytics improve quality control?
Predictive analytics analyzes patterns in production data to foresee potential defects or process deviations, allowing manufacturers to act before problems impact final products.
Why is micro-stop detection important for quality control?
Micro-stops — small, often unreported pauses — contribute to hidden downtime and reduced product quality. Identifying and reclassifying these events is critical to understanding root causes and improving efficiency.
Can MERLIN Tempus integrate with my ERP system?
Yes, MERLIN Tempus integrates seamlessly with major ERP systems to synchronize defect records, quality tickets, and production metrics for holistic operational visibility.
