Beacon Quality Blog

In our new Q&A column, we’re interviewing top manufacturing experts about industry trends and solutions to common quality challenges.

We recently talked with Casper Zublin, president of International Rubber Products (IRP), about rising quality expectations, Industry 4.0 and how to build a culture of quality. IRP’s three divisions manufacture liquid silicone rubber for medical device components (IRP Medical), precision rubber rollers (ABBA Roller) and elastomer components for aerospace and defense (MikronPMP Aerospace).

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With growth of digitalization in manufacturing, what does the future hold for Layered Process Audits (LPA)?  LPAs today generally verify human conformance to key processes with and outside set of eyes. But with automation, what will humans be doing?... and eyeballs won’t be as accurate as sensors.

Based on a presentation given by Murray Sittsamer and Richard Nave of The Luminous Group at our 2019 Beacon User Summit, this post will discuss the what layered process audit programs might look like in the future with advancement in technology. 

Industry 4.0 will be a $155 billion market by 2024, part of a rapid growth in technologies like machine learning and Internet of Things (IoT) revolutionizing the manufacturing industry. 

As Industry 4.0 picks up steam in automotive and aerospace manufacturing, we are witnessing an evolution towards more sensors, more data communication and more analytics. And while layered process audits (LPAs) could drive even more powerful quality insights and actions, companies also need to be aware of—and hopefully avoid—the potential downsides. 

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In 1982, W. Edward Deming’s Out of the Crisis outlined 14 points companies could learn from his success helping drive the industrial boom of post-WWII Japan.

The idea that quality pays was revolutionary at the time. Today, another revolution is taking place. Industry 4.0 represents a tectonic shift in manufacturing technology focused on automation, data exchange and interconnected cyber-physical systems.

But these massive changes don’t make Deming’s points any less relevant today. In fact, Industry 4.0 reinforces many of Deming’s 14 points—and can help the next generation of quality leaders relate to these foundational concepts.

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