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Quality Management - Practical Examples for the Prevention of Scrap. Rework. Variations. Missing parts. Complaints. Miscalculations.

Discover how companies in our network optimize their production quality and identify error sources early by leveraging modern IoT sensors and data analytics. Could you potentially reduce waste by recognizing quality deviations in real time and taking direct countermeasures?

over
1700 + Projects

Companies that successfully implement IoT/IIoT applications

Companies from our community that are already successfully implementing IoT and IIoT applications in practice.

Solution Examples > Quality Management

Your use case has already
been successfully implemented.

How do companies from our network successfully implement Predictive Quality with IIoT? Our tried-and-tested use cases show you data-based approaches that minimize product defects and optimize production processes.

Efficient process data visualization for the industry

Efficient process data visualization for the industry

Process data visualization is essential in modern production environments. With the IoT platform ALD EXPERT GR...

Automotive Production

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06. February 2025

Documentation and traceability in metallurgy

Documentation and traceability in metallurgy

Melt review sheets enable the precise recording and tracing of all process data in metallurgy. Real-time monitoring, automated documentation and integration into ERP and MES s...

Metals and Electronics Production

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23. January 2025

Smart supply chain: Development of the batch size 1 production line

21. November 2024

Pharma 4.0 made easy: IT/OT integration for safe, smart GMP solutions

Pharma 4.0 made easy: IT/OT integration for safe, smart GMP solutions

You are an IT manager, production manager or IIoT security expert i...

Pharma and Health

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08. November 2024

Discover proven solutions for Predictive Quality

Imagine production errors being detected before they occur – thanks to IIoT-powered analytics.

Industry challenges – do these sound familiar to you?

  • How can I detect quality deviations early?
  • How can I integrate Predictive Quality systems into existing production processes?
  • Which technologies and partners can support me in the implementation?

Our platform provides the answers.

Discover proven IIoT solutions that improve your production quality and reduce errors – supported by leading experts and technologies.

Proven IIoT use cases for Quality Management

Predictive quality is the key to greater efficiency and customer satisfaction. Our platform shows you tried-and-tested use cases that demonstrate how companies from our network optimize production quality through IIoT!

Coating Monitoring

Irregularities in, for example Irregularities in the coating process, for example, lead to quality defects. IoT-supported sensor technology measures temperature, humidity and particle concentration in real time. Automatic adjustment of the coating parameters ensures a flawless, uniform coating.

Material warping and deformation

Variations in temperature or pressure can cause material distortion and production defects. IoT sensors and associated software monitor critical parameters during production—such as in the coating of turbine blades—and dynamically adjust processes to prevent deformation or cracking.

Reduction of Rejects

High rejection rates put a strain on production for many companies in our network and drive up costs. IoT sensors and data analytics help detect and eliminate error sources at an early stage. By monitoring machine parameters in real time, quality fluctuations can be minimized, and rejects can be sustainably reduced.

Tool Wear

Tool wear leads to quality fluctuations and increased rejects in many companies. Many rely on vibration and force sensors that detect wear conditions in real time and enable early replacement.

Humidity and Particle Measurement

Fluctuations in humidity or an excessively high concentration of particles can impair production processes and lead to defective coatings or material contamination. IoT sensors measure these environmental parameters in real time and enable automatic adjustment of process conditions to avoid rejects.

Fluctuations in Gas Flow

An unstable gas flow can have a significant impact on the quality of coating or melting processes, for example. IoT-based monitoring systems analyze the gas pressure and flow in real time and regulate it dynamically to ensure even material distribution and optimal process conditions.

Fault Detection

The smallest deviations in production processes can cause errors that are difficult to detect and result in high costs later on. IoT systems record process data, analyze patterns and detect anomalies at an early stage so that corrective measures can be initiated immediately.

Vacuum Leaks

In many manufacturing processes – for example in vacuum-based systems – even the smallest leaks are critical, as they impair material quality and process stability. IoT sensors continuously monitor the negative pressure and detect leaks immediately to prevent production downtimes and quality losses.

Water Quality & Purity Levels

With smart IoT sensors, water quality is monitored in real time. Parameters such as pH level, nitrate content, dissolved oxygen, and conductivity are continuously measured to detect deviations early and ensure compliance with quality standards.

Invisible Microcracks

Microcracks are often invisible to the naked eye but can significantly reduce the strength and lifespan of components. With IoT-powered image recognition and non-destructive testing methods, microcracks can be detected at an early stage before they lead to structural issues.

Correlation of Production Parameters

IoT-powered analytics examine the relationships between machine settings and product quality. This data helps identify faulty processes and make targeted adjustments to ensure consistently high quality.

Detect Material Residues

Material residues in containers or larger machines and plants of the companies in our network disrupt processes and impair the quality of the end products. IoT systems identify residues through optical or chemical analysis and ensure timely cleaning or adjustment of production parameters.

Our partners with tried-and-tested IoT/IIoT solutions

Providers from our network whose IoT and IIoT solutions have been tried and tested in practice.

How do you successfully implement Predictive Quality?

Do you want to improve the quality of your products and processes with industrial IoT data or have you already planned your first steps? But you are faced with a variety of solutions and providers and are looking for a clear way to make optimum use of existing data and knowledge?

Quality Management and Predictive Quality require the targeted interaction of data-based technologies, strong partners and tried-and-tested approaches in order to detect errors at an early stage, avoid deviations and sustainably increase process efficiency.

Data Acquisition

The basis of every IoT and IIoT project lies in data acquisition and pre-processing (EDGE). The data from the field and control level can be transmitted either directly by wire or wirelessly. Operational parameters such as temperature, pressure, force, or production data in real time are captured – and made available for any use case.

Data Transmission

A seamless transfer of captured data is essential. Many companies combine wireless and wired solutions depending on the use case – for secure data transmission to the cloud or locally. Suitable networks for distance, data load and environments as well as high security standards are crucial in order to avoid downtimes.

Device Management

Efficient device management for IIoT devices enables companies in our community to centrally manage the entire life cycle, including automated updates and certificate management. Our partners are working on solutions to reduce operating costs through automation, minimize downtimes and achieve high efficiency through scalable solutions and optimized interfaces.

Data Integration

Data only becomes valuable when it is seamlessly integrated into existing IT and OT systems. A strong connection between machine level, MES, ERP systems and other business solutions enables efficient processes and consolidated insights. Keywords: Data Warehousing, Data Lake and Database (storage)

Data Standard (Communication)

Many companies do not have standardized access to machine and device data right through to their IT systems. Standards such as OPC UA, LoRaWAN and mioty enable seamless integration from the edge to the cloud. OPC UA, for example, connects OT and IT by transferring data via edge gateways to cloud services such as Azure Event Hubs or Kafka and tools such as Grafana or Power BI. Our partners ensure that these standards can be used efficiently.

Data Standard (Master Data)

Master data for products and services is often not uniformly classified and is available in data silos. When implementing use cases such as traceability, digital type plates, the digital product passport (DPP) or the product carbon footprint, this leads to high costs in data engineering due to duplication of work and inefficient processing. Uniform data formats, standardized product descriptions and technical concepts such as the Asset Administration Shell (AAS) are therefore crucial.

Data Visualization

The visualization of IoT data makes it possible to display complex information such as alarm trends, golden batch or process dashboards in intuitive reports. Customizable dashboards on standard tools help to analyze real-time data, identify trends and make informed decisions. Low-code solutions are also available.

Data Analysis and Evaluation

IoT/IIoT data analysis provides real-time insights into processes through, for example, data event-driven apps, real-time analytics, and root cause analytics. Tools such as MVDA, OEE, process KPIs and Predictive Maintenance can be used to identify anomalies and optimize processes. Low-code solutions also facilitate rapid implementation.

Data Security

Protection against unauthorized access, theft or manipulation is an issue for every company in our network. Our partners are working on solutions for the optimal use of digital identities and encryption technologies for secure access and communication of your devices, machines and systems.

Services

The services of our partners support companies from our network in the implementation and optimization of IoT solutions. This includes consulting, individual customization, training and technical support. The aim is to make processes more efficient, integrate systems seamlessly and derive maximum benefit from IoT/IIoT data.

Benefits of Predictive Quality:
Prevent errors, ensure quality

Early Error Detection

IoT sensors monitor parameters such as temperature, pressure, humidity, or vibrations in real time. This allows deviations to be detected before they negatively impact product quality. It saves costs by preventing defective products and increases the reliability of your processes.

Optimization of Production Parameters

Predictive Quality enables the analysis and correlation of machine settings and product quality. This allows optimization potential to be identified and adjustments made to ensure consistent quality.

Error Prevention Through Simulations

With digital twins, production processes can be simulated to identify potential sources of error in advance. This helps prevent unwanted production downtime and increases efficiency.

Efficient
Root Cause Analysis

Predictive Quality uses IoT data to analyze the causes of quality issues more quickly and accurately. This allows production problems to be systematically eliminated and future errors to be prevented.

Improved Resource Utilization

Through precise analyses and process controls, Predictive Quality reduces scrap and optimizes the use of materials and energy. This lowers costs and enhances the sustainability of production.

From manufacturer to solution provider

Are you a machine and plant manufacturer working on digital solutions in your company? You know it too: Digitalization brings new challenges that you’d like to discuss with an experienced partner. We help you make your machines future-ready, build the right infrastructure, and develop innovative business models. Together with you and our strong partners, we find tailored solutions that optimize your processes and create new added value.

Centralized customer portal for Condition Monitoring

Offer your customers a powerful portal for accessing master data, technical documentation, and contact information. The integration of shift logs and data-sharing functions enhances transparency and increases the efficiency of your services.

Maintenance calendar with self-service features

Make maintenance planning easier for your customers with digital manuals and clear troubleshooting options. The maintenance calendar ensures that maintenance measures are carried out efficiently and without delays.

Seamless ecosystem integration for greater flexibility

Seamlessly integrate knowledge and data into a comprehensive ecosystem. With API interfaces and export options, you can provide your customers with a connected and flexible solution.

Smart plant integration and seamless commissioning

Support your customers in the efficient commissioning of new plants. With digitally supported processes, system integration and production starts are smoothly executed.

Optimized user integration and feedback tools

Give your customers the opportunity to better understand their end users. Through feedback management and customer traffic analysis, services can be tailored and optimized.

Predictive Maintenance

Help your customers act proactively rather than reactively. Predictive Maintenance enables data-driven maintenance planning, reduces downtime, and increases machine availability.

Intelligent recipe management for production lines

Digitize your customers' recipe management to make production processes more efficient. Changes and synchronization can be implemented across locations to save time and resources.

Transparent reports and compliance made easy

Provide your customers with solutions for comprehensive reporting that covers warranties and legal compliance. Transparent processes build trust and foster long-term partnerships.

Centralized customer portal for Condition Monitoring

Offer your customers a powerful portal for accessing master data, technical documentation, and contact information. The integration of shift logs and data-sharing functions enhances transparency and increases the efficiency of your services.

Maintenance calendar with self-service features

Make maintenance planning easier for your customers with digital manuals and clear troubleshooting options. The maintenance calendar ensures that maintenance measures are carried out efficiently and without delays.

A partner who understands your challenges

IoT Use Case is more than a network – we are your trusted advisor with a focus on trust, integrity and added value. Regardless of whether you want to implement a use case or are looking for the right entry point:

Our expertise and our network support you in making well-founded decisions based on practical experience that achieve your goals. With our experience from over 1,700 projects, we understand the hurdles, pitfalls and opportunities – and help you to overcome them.

Tried and tested solutions
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IoT Use Case – Your community for implementing IIoT

Join our IoT community and learn how other companies have successfully implemented Condition Monitoring. We provide you with a platform to discover best practices and find the right IoT solutions for your challenges.

Share and expand experiences

Exchange ideas and approaches on IIoT use cases such as Predictive Quality or Digital Service.

Develop use cases further

Share tips and best practices across functions and inspire other companies.

Discuss trends and challenges

Learn how others use IIoT technologies to solve challenges and identify trends early on.

Get inspired or find targeted solutions
– Your IIoT use cases at a glance.

Discover proven approaches for real-time monitoring of machines and facilities. Minimize downtime and ensure the availability of your processes.

React efficiently when it matters. Reduce downtime and keep your production running.

Plan maintenance work smarter and data-driven. Prevent failures with solutions that identify problems before they occur.

Track materials and products across the entire supply chain. Meet regulatory requirements and build trust through transparency.

Increase the efficiency of your facilities. Optimize operations, maintenance, and management with innovative technologies.

Reduce energy costs and optimize consumption. Use real-time data to make sustainable decisions.

Ensure your product quality with state-of-the-art technologies. Avoid rejects and identify sources of errors early.

Simplify your processes with paperless workflows. Benefit from centralized access and efficient data management.

Protect your assets and processes. Smart technologies help detect and minimize risks early.

Manage vehicle fleets efficiently and smartly. Optimize routes, reduce costs, and improve operational safety.

Protect your employees with innovative IoT solutions. From contaminant detection to emergency communication – ensure maximum safety.

Opt for eco-friendly and sustainable solutions. Monitor emissions and optimize resource consumption.

Implementation Support

Receive practice-proven solutions for your use case

Use our free beta network database until 31.12.2025 to find practice-proven IoT solutions. Simply register and get direct access to tried and tested solutions from real projects, provided by trusted partners and companies. Benefit from the latest information, success stories and a preview of use cases that will drive your projects forward.

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projects implemented

Get free access - only until 31.12.2025!

FAQ

Ihre Fragen - unsere Antwort

Hinterlassen Sie Ihre Kontaktdaten und eine Nachricht zu Ihrem Anliegen. Wir vereinbaren einen Termin und schauen gemeinsam in die Datenbank.

Im Termin besprechen wir gemeinsam Ihre spezifischen Herausforderungen und Ziele. Anschließend präsentieren wir Ihnen entweder im Termin oder im Nachgang per Liste passende praxisgeprüfte Lösungen aus der Datenbank, die auf Ihre Bedürfnisse zugeschnitten sind. Der Termin dauert in der Regel 30 bis 60 Minuten.

Unsere Datenbank ist nach Branchen, Use Cases, Funktionsbereichen, Asset-Types und Technologien strukturiert. Je nach den Eigenschaften Ihres Use Cases schauen wir gemeinsam in die Datenbank und finden die für Sie relevanten Lösungen.

Ja, die Nutzung der Beta-Version ist bis zum 31.12.2025 kostenlos. Es gibt keine versteckten Kosten.

Der Zugang ist kostenlos, weil wir uns in der Beta-Phase unserer Plattform befinden. Ziel dieser Phase ist es, Feedback von Nutzern wie Ihnen zu sammeln, um unsere Netzwerk-Datenbank optimal auf die Bedürfnisse der Community anzupassen. Gleichzeitig möchten wir Ihnen die Möglichkeit geben, die Vorteile praxisbewährter Lösungen aus erster Hand zu erleben und Ihre IoT-Projekte erfolgreich voranzutreiben.

Unser Interesse bei IoT Use Case ist es, praxisbewährte IIoT-Lösungen zugänglich zu machen, die Unternehmen dabei unterstützen, ihre Digitalisierungsprojekte erfolgreich umzusetzen. Mit unserer Plattform und den zugehörigen Services schaffen wir eine vertrauenswürdige Umgebung, in der Best Practices und konkrete Anwendungsbeispiele im Mittelpunkt stehen.

Nach dem Termin erhalten Sie eine Zusammenfassung der präsentierten Lösungen sowie Zugang zu weiterführenden Informationen und Ansprechpartnern.

Die Lösungen in unserer Datenbank stammen von vertrauenswürdigen Partnern und Unternehmen aus unserer Community, die erfolgreich IoT-Projekte in der Praxis umgesetzt haben. Jede Lösung basiert auf realen Anwendungsfällen und wurde unter realen Bedingungen von mindestens einem Kunden oder Anwender getestet.

Die Inhalte werden täglich mit aktuellen Lösungen, Referenzen und neuen Use Cases aktualisiert.

Ja, wir freuen uns über neue Lösungen. Wenn Ihre Lösung bereits in der Praxis erfolgreich eingesetzt wurde, können Sie diese in die Community-Datenbank einbringen. Sprechen Sie uns dazu einfach über unseren Kontaktbereich an oder senden Sie uns einfach eine Nachricht mit den Details Ihrer Lösung an:

Yes, on our platform we show you an excerpt of success stories, references and solution examples from the database.

Kein Problem! Unser Team hilft Ihnen gerne weiter. Senden Sie Ihre Fragen einfach an:

kontakt@iotusecase.com

+49 (0) 30 57714477

Wir freuen uns darauf, Ihnen weiterzuhelfen!