The rapid pace of product innovation, evolving manufacturing methods, and skilled labor shortages are putting increasing pressure on traditional Quality Assurance/Quality Control (QA/QC) approaches. At EWI, advanced QA/QC has been an ongoing focus, leveraging our expertise in manufacturing processes, sensor integration, and data science to develop real-time, automated solutions that can:
- Enable 100% inspection
- Provide instant, actionable feedback to the operator
- Automatically react to and solve defects or process deviations
To enable 100% inspection, EWI combines real-time sensing, machine learning, and production-representative datasets to generate real-time quality predictions for individual components. These predictions allow manufacturers to reduce destructive testing, minimize scrap associated with batch-based inspection, and reduce work-in-progress. In addition, these predictions can support predictive maintenance efforts and provide valuable insights for warranty claims.
To deliver instant, operator-actionable feedback, EWI develops datasets that include real production failure modes, enabling predictive systems to not only flag defects, but also to identify their likely causes. This provides operators with the information they need to prevent issues before they occur, shorten troubleshooting time, and improve overall process reliability. These tools are particularly valuable for less experienced operators who benefit from the built-in diagnostic guidance.
EWI is applying quality predictions within automated control loops to dynamically adjust process parameters and prevent defects before they occur. One current effort uses predicted weld dilution to modify welding travel speeds in real time, avoiding lack-of-fusion issues and demonstrating how predictive QA can drive closed-loop, self-correcting manufacturing.
Delivering these solutions requires cross-disciplinary expertise in sensing, nondestructive evaluation, automation, process physics, and data science — capabilities that EWI brings together to support advanced QA/QC innovation.
See How EWI is Shaping the Future of QA/QC
Technical Papers
Our technical papers highlight the methods, results, and innovations driving predictive quality systems at EWI:
- A Streamlined System to Capture High-speed Video and Process Data for Manufacturing Applications
- The Effects of Subsystem Performance on Static and Dynamic Properties of Inconel 718 Built with Laser Powder Bed Fusion*
- Investigation of monitoring methods for ultrasonic metal welding*
*These papers are published by a third-party. EWI Cooperative Research Program participants can request copies through EWI Library Services.
EWI Expert Analysis
Gain deeper insight into QA/QC trends and technologies through articles and commentary from EWI experts:
- The Future of QA/QC: Turning Manufacturing Quality into a Competitive Edge
- Simple Solutions Can Mean Smarter QA/QC
EWI Technology Podcast: The Future of QA/QC in Manufacturing
In a recent episode of the EWI Technology Podcast, a panel of EWI experts — Alex Kitt, Logan McNeil, and Connie Lamorte — discuss how automation, real-time data, and AI are reshaping QA/QC in manufacturing. The conversation covers when to invest in a QA/QC program, how automation improves product quality, and what’s next for advanced sensing and machine learning. Watch the episode below, or listen wherever you get your podcasts, to hear how EWI is driving smarter QA/QC.
Contact Us
If you would like to learn more about EWI’s advanced QA/QC capabilities, please contact Alex Kitt at [email protected].