From paper and digital, to NoTouch-NoScreen voice interactions to complete checklists and forms. Remove the constraints of the screen to unleash the completion of forms and checklists in real-time during inspection and quality controls operations
SPIX industry introduces a breakthrough innovation that allows the field inspectors and quality controllers to complete checklists and forms 100% by voice, hence improving the compliance with the inspections norms and standards.
Inspection and quality control are critical for the performance the manufacturing industry. The associated data and the way to collect it are described in norms and standards that the industry needs to comply with to get the necessary certifications for their activities or personal.
Beside some automated processes of control, most of the controls and inspections activities rely on the human expertise of the operators in charge. Quality controllers and site inspectors have the responsibility to assess a situation regarding the norm, raise alerts, stop a production process, or escalade problems. The result of their work ends-up in check lists or forms, which need to be completed as precisely as possible, on-site, and in real-time.
Constant investments are made by industrials to make sure that the field inspectors or the quality controllers have the right tools to operate. Major steps forward have been made with the introduction of digital checklists. Nevertheless, issues still exist regarding the real-time and onsite completion of the forms, and the potential safety breaches introduced by the digital tools used in operations.
Quality process, inspection, controls, norms and standards
Quality processes described in norms and standards are supported by field inspections and quality controls. Beside the automated part of the inspections, most of the inspections and quality control data are generated by men and women of the industry in charge of this process. Such data need to be collected in real-time, in front of the object or situation under investigation to be compliant with the related norms and standards.
Quality process, inspection & control tasks, and field operators
The quality process in the manufacturing industry is responsible for ensuring that the products meet the quality standards set by the company or by the relevant regulation authority. Such regulation is most of the time described in norms and standards. Quality control and inspection tasks are implemented to support the quality process, the compliance, and safety of products, of field operators, and of facilities.
To ensure that products, installations, or equipment comply with quality standards, to identify and correct non-conformities, and to contribute to the continuous improvement of manufacturing processes, the following tasks are included in the quality control process:
- Product inspection: The quality controller or inspector visually and using measuring tools inspects finished products or installations to verify compliance with technical specifications and established standards. Inspection reports are generated to insure the proper traceability and big-data analysis for further improvement as well as for insurances and other relevant certification authorities.
- Manufacturing Process Control: The quality controller monitors and evaluates the various stages of the manufacturing process to ensure that operations are carried out in accordance with established procedures, norms, and standards.
- Analysis of non-conformities: In the event of non-compliance (non-quality) or undesirable event (non-conformity), the quality controller analyzes the causes of the defects, identifies the corrective actions to be implemented to remediate the situation, and proposes solutions to prevent recurrences.
- Participation in quality audits: The quality controllers and inspectors participate in internal and external audits to assess the compliance of manufacturing processes, facility management, and products with the quality standards established by the company or by certification authorities. Quality audits manipulate many data and forms for logs, certification reports, and action follow-up purposes.
The person in charge of the compliance of the quality process performs inspection and control tasks, which generate reports, forms, and checklists, to communicate the results and follow the requested actions.
The quality control process is implemented through the mean of inspections and control tasks to evaluate the compliance with standards, worker’s and user’s safety, and to ensure the proper and safe functioning of equipment and facilities in the industry. Inspection and control tasks are performed by men and women of the industry using the following technics and methods:
- Visual inspection: Visual inspections and controls is the process of visually examining a product, component, installation, or facility for apparent defects, or manufacturing anomalies, damage, etc. Beside the automated part with inline cameras, this is one of the most common inspection and control tasks done with the eyes or with the help of magnifying tools (glasses, reveling pigments, …). The result of the visual inspection is a report, assessing the quality of the inspected element, and listing the potential defaults.
- Dimensional measurements: Dimensional controls involve taking precise measurements of the dimensions of a product, a component, or an installation to verify that they comply with technical specifications. Measuring tools such as gauges, micrometers, calipers, etc., are used to perform these inspections. Some of them are automated with robots or similar tools, others are made by humans. Such dimensional inspections and controls generate tables of measured values stored in forms and checklists. Such forms are used for the traceability of the quality process.
- Materials Control: This type of inspection task consists of verifying the quality and conformity of the materials used in the manufacture of the products. Composition, strength, hardness tests, etc., can be performed to ensure that the materials meet the requirements. Usually done in laboratories, and mainly automated, the analysis of the results relies on the experts who are responsible to generate and validate the appropriate report.
- Functional testing: Functional testing is performed to verify that the product or system is performing properly according to the defined specifications and requirements. it includes performance tests, stress tests, simulation tests of operating conditions, etc. Functional testing can be made onsite, in various operating conditions. For example, as illustrated later, the functional testing of extinguishers enters in the category of the functional testing.
- Inspection of equipment and facilities: As part of preventive maintenance, inspections and controls are carried out on equipment, machinery, electrical installations, ventilation systems, etc., to detect signs of failure, potential risks and ensure their proper functioning. As illustrated later, the visual inspection of heavy vehicles is a routine activity on construction sites.
- Regulatory compliance monitoring: Inspections and controls are also conducted to ensure that products and processes comply with relevant standards, regulations, and guidelines. This involves verifying compliance with safety, quality, environmental standards, etc.
The inspection and control tasks play a major role in the quality process of the industry. The generated data is of paramount importance to assess the compliance to the associated norms and standard.
Samples of industrial norms and standards
Norms and standards play a critical role in any industrial process. For example, norms and standards are used to promote workplace safety by establishing clear guidelines and best practices to be followed to prevent accidents, reduce occupational hazards, and ensure the protection of workers. Norms and standards constitute the foundations of the quality processes in the industry to ensure the quality of the production, or the performance of systems.
All standards and norms help companies establish robust quality control and inspection processes, ensure compliance with regulatory requirements, warranty the safety of their operations, and continuously improve the quality of their products. Besides, it is important for businesses to comply with these standards to maintain competitiveness in the market and to ensure customer satisfaction.
Industrials have many reasons to comply with standards and norms, whether regulatory, quality, safety, competitive advantage, or environmental: the data collected during inspections and controls are critical to assess their compliance to the selected norms and standards.
Among all the norms and standards, some of them apply to the quality processes of the industry, thus describing the inspection and control tasks. Some of the forms and checklists used for inspection and control are described in the corresponding norms and standards. To illustrate, some samples below:
- ISO (International Organization for Standardization) Standards: ISO standards like ISO 9001 (Quality Management System) and ISO 13485 (Medical Devices) establish requirements for inspection and quality control processes in various industry sectors.
- OHSAS 18001 / ISO 45001: This international standard establishes the requirements for the management of safety at work. It aims to ensure a safe and healthy working environment for employees, prevent professional accidents and illnesses, and improve industrial safety performance.
- ISO 12100 standard: This European standard defines the basic principles for the design of machinery and work equipment to ensure the safety of operators and people working nearby. It establishes criteria for assessing the risks associated with the use of machinery, and for implementing appropriate safety measures.
- NIST (National Institute of Standards and Technology) Standards: NIST establishes measurement and calibration standards for the tools that are used in inspection and control processes. The NIST standard ensures accurate and reliable results in inspections and control tasks where measurement tools are involved.
The compliance with standards and norms is essential for the industry because it guarantees legal conformity, protects the company’s reputation, reduces risks, facilitates access to international markets, and promotes continuous improvement of performance.
Quality controls and inspection data, limits of the digital transformation
The accuracy of the data collected during quality controls or inspections is mandatory to assess the compliance with the norms and standards associated to the quality processes in the industry. For automatic processes (cameras, sensors) the quality of the data depends on the equipment and on the associated algorithms.
For human generated data, the game is completely different… The analysis of the type of data generated by the men and women in charge of the inspections and controls will help us understands their difficulties in using traditional digital tools, hence explaining the advantage of voice first interactions to collect inspection and control data.
With its NoTouch-NoScreen proposal, SPIX industry changes the game for the quality controllers and field inspectors.
Typical data associated to human inspection and control
An operator of inspection or quality control in the industry manipulates various types of data to assess the compliance of the products, object, site, or installation to the associated norms and standards.
The quality of the data collected onsite participates to the strength of the assessment of the compliance to the norms and standards in the industry.
The examples below describe some of the data manipulated by field inspectors and quality controllers, and the impact of their quality and the assessment of the compliance to norms and standards. For each data, its quality criteria are defined.
- Dimensional measurements: Inspection and control operators use dimensional measurement to verify the physical properties and geometry of manufactured parts, installations, production sites, … Such measurement requires hand tools and the report of many values. Some time, conversion between the measured and the reported units are required. Tables of hundreds of measurements are common in certain industries: the nuclear industry for example.
The quality of the “dimensional measurement” data depends on several criteria:
1- The calibration of the measurement tools,
2- The availability of hands and position of the body of the operator,
3- The sequential report of the measured value to avoid the mismatches between the measurement and the report.
Criteria 2 and 3 are difficult to fulfill for inspectors and quality controllers on the move.
- Defect identification and classification: The visual inspection performed by field operators ends-up by the qualification of the nature of potential defects. Depending on the industry, defects can be classified according to different categories, severity, emergency. Such categories are different for the automotive industry and for the construction industry. The nature of the defect or its criticality are typically selected from lists of predefined defects.
The quality of the “identified defect” data depends on the following criteria:
1- The highlighting and accessibility of the potential defect,
2- The capacity of the operator to use the appropriate classification to describe it,
3- The capacity for the operator to add a detailed description of the context or the environment, such as root cause, or consequence of the defect,
4- The ability to report each identified defect one after each other to avoid the mismatches between the defects and their description.
5- The completeness of the description of the defect is of paramount importance for its proper post treatment and for the ranking of the remediation actions.
Criteria 2 to 5 are difficult to fulfill for inspectors and quality controllers on the move. For example, the redaction of a detailed description of an identified defect while moving in an industrial area is complex.
- Conformity criteria: A system, a product, an installation conforms or not to its specification. The inspector and quality controller have the possibility to declare conform or non-conform any item under investigation. The conformity criteria are selected from a binary list of choice: conform / non-conform, Ok / non-Ok, … The declaration of non-conformity has a huge impact on the production process. A non-conformity not reported at the right time might have a huge impact on the business: loss of image, economical penalty, recall of equipment, …
The quality of the data associated to the “conformity criteria” depends on:
1- The clear understanding of the criteria by the operator. Said differently, the avoidance of ambiguity on the evaluation criteria independently of the operator,
2- The ability of the operator to report the conformity for each criterion one by one, without “cutting the corners” by checking many items at once.
3- The capacity for the operator to add a comment in the case of non-conformance, to help the understanding during post-treatment, and accelerate the remediation plans.
It is difficult for the inspectors and quality controllers on the move to comply with all the described criteria. For example, novice controllers might not be sure of the criteria to use to evaluate the conformity. All of them have difficulties to report an relevant comment in the case of non-conformities.
- Item identification and description: Any object, site, machine, installation is identified with a unique alphanumeric reference. This reference can be a barre-code for example. In many situations, this reference is a list of letters and numbers, with or without a defined pattern, that depends on the industry. Despite the barre-code reference reported and stored by a mobile scanner, the inspector reads the reference and reports it in the inspection report. In addition to its reference identification, any item can be described with a small number of words. With a format like Short Message System (SMS), a description often includes the name, the location, or the process it belongs to. Item description is reported as a short free text.
The quality of data associated to the “item identification and description” relies on:
1- The quality of the barre code to enable automatic scanning and referencing.
2- If the barre code is scratched, or if scanners are not available, the quality of the reference depends on the ability of the operator to report a suite of alpha-numerical values in a digital system.
3- The capacity for the operator to add a description of the item, to help the understanding during post-treatment.
Criteria 2 and 3 are difficult to fulfill for inspectors and quality controllers. For example, the re-copy of reference numbers from a physical equipment to a digital system might be a source of mistakes.
- Picture of the situation: A picture of the situation can complement the text description of the situation a picture can be added. Such picture helps to understand the context of the defect, or the reason of the non-conformity.
The quality of “picture of the situation” depends on the camera available on the device of the operator. Some pictures require comments to precise its context, to precise the reason the picture has been taken, or what needs to be seen in it.
As for many other data, the redaction of a comment by field inspectors on the move is complex.
- Action already taken: When an action is taken immediately to mitigate the risk associated to a potential defect, a description of the action is expected. The description of the action taken immediately is reported as a long free text.
The “action already taken” consists in a comment, most of the time located at the end of groups of controls or after the description of critical defects. Such comment helps to understand the level of emergency to put in place a remediation plan.
The quality of the description of the actions already taken depends on the capacity for the operator to add a comment.
Most of the data relevant for the inspection and quality control are complex to report by the field operator, either on paper or on digital equipment.
Conformity criteria | Defect classification |
Conformity criteria are most of the time reported on paper as well as on digital equipment as check boxes. Check boxes can also be used to certify that a task has been carried out. On paper, it is not possible to verify that every box has been validated individually, on digital equipment yes. | Defect classification can be described as lists of predefined items. For example, the consequence, the likelihood, and the risk rating are made of 4 or 3 possible choices. On paper such selection is made by underline of the proper choice, on digital forms by clicking on the appropriate button. |
Limits of the current Digital Transformation
Traditionally, inspection data are reported on paper onsite and copied to any type of digital backend systems afterward. A significant effort of digital transformation has been made by the industry to remove the paper report in the inspection and quality control work.
This digital transformation promises to overcome all the difficulties of the field inspectors and quality controllers to report data in real-time, and therefore to improve the compliance of the industrials to the relevant norms and standards. The digital transformation provides two major improvements:
- Time saving, with the suppression of the time to re-copy the data from paper to digital.
- Traceability, with the overall improvement of data storage and retrieval.
Nevertheless, the introduction of digital solutions for inspectors and quality controllers does not releases the hands of the operators, nor simplifies the redactions of comments on the field.
The transition from paper reports to digital tools introduces many improvements, but also creates additional difficulties. Among them, the safety issues create by the removal of the gloves and the free falls due to visual distractions, hence creating difficulties to generate reports, record measurements, or comment defects in real-time.
The introduction of digital tools for inspection and quality control in the industry has many benefits in terms of efficiency, accuracy, and data traceability. However, it can also lead to new constraints and potential risks. In addition to the known risks related to cyber, data security, software and hardware robustness, other risks associated with the use of digital tools are more directly related to the inspection operators:
- Carrying an equipment: A tablet is too heavy a smartphone is too small! One already working on the shop floor certainly heard that twice a day. Consequently, the digital equipment is most often left apart, and used after the operation. This causes a major breach in the compliance with most of the norms and standards in the inspection and quality control domain, as the data are not reported in real-time.
As stated in the previous section, the measurement data or defect classification are less accurate when reported afterward. This diminishes the global quality of the data reported from the field, and therefore the compliance with the norms and standards.
- Gloves removal: Using a tablet or a smartphone with professional gloves can be a nightmare. Therefore, inspectors and quality controllers most of the time remove their gloves to report their data in digital tools, hence creating a safety breach and a non-compliance to the safety rules and norms. Specific gloves exist, but not all of them are compatible with professional working environment (chemical hazard for example).
The action of removing the gloves at work is a clear breach of the safety norms and standards for many industries.
- Falls on the same level: The number of accidents classified as “falls on the same level” is increasing sharply in the industry. Falls on the same level are responsible for nearly 20% of workplace accidents in France, with a strong correlation with the introduction of digital equipment for the work forces. This might be the consequence of distractions due to the digital equipment while walking on industrial sites.
The increase of incidents and accidents in the industry creates a non-compliance regarding the safety norms and standards objectives of the industry. For example, all the QHSE standards target a diminution of the incidents.
- Training and adaptation: The introduction of new digital tools may require a period of adaptation and training for inspection operators, especially for those who are not familiar with the technology. It is important to provide adequate training to ensure effective use of the tools. Despite the training, if the user interface of the digital tools is not easy to use (usable, useful, and acceptable), the inspection and quality control operators may be reluctant in using it.
Consequently, the digital tools might be used off-site, after the inspection, hence reducing the global quality of the data collected on the field.
As a conclusion and regarding the compliance to the norms and standards, the introduction of digital tools for quality control and inspection generates two issues:
- The digital tools hinder the generation of real-time data, as the equipment (tablet or smartphones) is not compatible with operational use in working environment: non-compliance on the quality of the data.
- The use of tactile screen and the focus on the screen itself might generate new risks for the operators themselves, while removing their gloves, or falling while walking, which introduces non-compliance on safety rules.
A Voice Assistant to fully comply with the norms
The integration of a voice assistant into the daily life of industrial inspection field operators can bring multiple benefits and facilitate their tasks. Moreover, it may overcome the dependence on the screen and on the hands to restore the full compliance to norms and standards.
A Voice Assistant enables the field inspectors and quality controllers to use digital tools releasing the constraints of the screen and releasing the hands. The NoTouch-NoScreen innovation is a breakthrough in the use of digital tools while on the move in industrial environments.
The following observed benefits of voice assistant for industrial inspection operators and quality controllers, are listed with the special point of view of the compliance to the norms.
- Real-Time completion of information: A voice assistant allows the operator to complete the requested information (measurement, visual inspection, defects, …) in real-time during the operations. This is a major improvement, compared to paper or traditional digital tools. It helps to comply with the norms and standards by drastically improving the quality and accuracy of the collected data.
- More accurate documentation: The voice assistant can allow operators to dictate inspection reports, observations, recommendations, comments, description, and actions already taken, directly in the field, making it easier to document inspection and quality control activities. A more complete documentation helps to strengthen the compliance with the norms, as the documentation is completer and more accurate.
- Enhanced Safety: By allowing operators to keep their hands free and focus on their work environment, a voice assistant helps increase safety during field inspection operations. Removing the constraints of the gloves avoids creating a safety breach, hence improving the compliance to the QHSE and OSHA norms and standards.
The integration of a Smart Voice Assistant that implements the NoTouch-NoScreen principles for industrial inspection field operators can offer them a practical, efficient, and versatile tool to improve their performance, efficiency, and comfort at work.
SpixForCheck: a NoTouch-NoScreen voice experience for field inspectors and quality controllers
According to a German study from the IPRI institute, Spix is the only European intelligent voice assistant 100% dedicated to technicians and operators in the industry. The 2022 Carnot Institute study confirms SPIX industry‘s unique place in the world of “Manufacturing AI” (operational artificial intelligence applied to industry).
Strong from such record, SPIX industry releases SpixForCheck, the first software solution fully dedicated to inspection and quality control operators that implements a Smart Voice Assistant to unleash the power of the NoTouch-NoScreen approach.
Voice Assistance: a disruptive innovation for the inspection
As stated before, the compliance to the norms and standards of inspection and quality control requires more than a digital transformation of the field operations. SPIX industry ambitions revolutionize this critical domain of the industry with its AI Voice Assistant SpixForCheck.
SpixForCheck is an intelligent voice assistant solution dedicated to inspectors and quality controllers. It provides a NoTouch-NoScreen Voice interactions to releases the constraints of the traditional digital tools.
The NoTouch-NoScreen approach solves the issues of the field workers while interacting with digital equipment. It releases the constraints of carrying or touching tablets smartphones, keyboards, or mouses to feed an information and removes the constraint of looking at small screens to get an information on the field. SPIX industry is a pioneer company introducing NoTouch-NoScreen applications based on the Smart Voice Assistant Spix that includes advanced voice interaction modes dedicated to such “voice first” interactions to digital content.
SpixForCheck brings together three types of complementary technologies for the deployment of a real NoTouch-NoScreen voice interface to digital tools for the field inspectors:
- Robust speech recognition technology capable of translating voice into text in industrial environments in the highest possible performance,
- A Smart Voice Assistance technology also called dialog agent or conversational AI interface to go beyond simple speech recognition and initiate a real intelligent dialogue between the assistant and a user. A text-to-speech technology is also used to provide audio feedback to the user.
- Dedicated voice interactions modes to help the inspector in the management of the checklists and forms, by voice only, keeping his hands free and his eyes focused on his environment and duty.
The idea behind this disruptive NoTouch-NoScreen voice interface innovation is to radically change the user experience of industrial inspectors, reconcile them with their digital environment, and help them comply with the norms and standards ruling their jobs. This innovation and its implementation in an industrial environment meet the ambitions of the Industry5.0 program from the EC.
Features of SpixForCheck for the inspection
For inspectors and quality controllers to work effectively with the help of a NoTouch-NoScreen voice interface, and for it to be “intelligent” in their work context, it must have characteristics specific to industrial applications:
- Natural Conversation: SpixForCheck allows operators to speak in natural language to trigger multiple actions, as if they were addressing their co-worker.
- Robustness to the work environment: SpixForCheck and its associated audio devices have been developed to withstand the constraints of an operational work environment: noise, humidity, heat, dust, mandatory PPE wearing, frequency bands, …
- Understanding the job: SpixForCheck allows workers to use all the words and phrases used in their inspections and quality control jobs. SpixForCheck feeds on the validated forms and checklist from the industry, or from the standardization organizations.
- Contextual intelligence: SpixForCheck understands a technicians’ voice requests based on their work context, inspection status, expected elements of forms and checklists.
Voice First inspection features
- Binary conformity choice
- Choosing items in long lists
- Selection in several lists
- Entering measurement values
- Entering alphanumerical values
- Entering a short text title
- Entering a free text comment
- Activation of the photo device…
Voice Assistance functions
- Step-by-step instructions completion
- Values confirmation, modifications
- Access to boundaries, verification of limits
- Modification of the previous value
- Recall of the instruction
- Voice presentation of the choices in lists
- Different level of validation: simple, critical
- Repetition of the instruction
- Repetition of the last input for validation…
SpixForCheck: how it works
The product SpixForCheck is a “all-in-one” solution, with a NoTouch-NoScreen voice interface. It includes the following elements:
- On the software side:
- 1 software license of the Spix voice assistant, voice recognition/synthesis (several languages are available), for Android operating system,
- 1 software license of the visual user interface, for Android operating system,
- On the hardware side:
- 1 smartphone, ruggedized for industrial use,
- 1 headset robust to noise, designed for industrial use,
- 1 set of safe box for storage, recharge for the headset and smartphone.
- On the documentation side
- 1 documented import format from the backend: YAML,
- 1 documented export format to feed the backend: JSON, CSV.
- Several checklists from different norms and standards as sample
- Option: an interface service to export/import into your own output format
To keep the interface to the IT of the industry as simple as possible, SpixForCheck proposes a static interface with the backend environment of the industrials. In other words, static export and import operations are used to get the existing checklists templates and feed the backend with the completed once.
The operational process can be described as follow:
- The checklists are exported from the backend in a neutral format that can be used by SpixForCheck. By default, YAML is used.
- The checklists in a neutral format are uploaded on the mobile device: tablet or smartphone, with Android operating system.
- The operator completes as much checklists as they want in mobility, from the checklist’s templates. SpixForCheck can be used offline, does not require any network or remote cloud to operate. The NoTouch-NoScreen voice interface enables to keep his hands free, move on industrial sites, and report all necessary data in real-time.
- The checklists can be generated by voice in disconnected situations, on the tablet or smartphone, and visually validated when completed prior to their “publication”.
- When back to the office, the generated checklists are uploaded to the backend server to be stored at the expected place. The export is made by default in JSON and CSV formats.
Expected benefits of SpixForCheck
To be used and accepted, both the industrial (the payer) and the operator (the user) need to find a direct benefit in the deployment of SpixForCheck.
Conclusion
The need from the industry to strengthen the quality process leads to more sophisticated norms and standards. Consequently, checklists and forms associated to quality controls and inspections become more complex and their quality and completeness more critical.
This generates a particular pressure on the field operators in charge of the inspection tasks and quality controls to complete the checklists and forms as precisely as possible, in real-time and without any missing data. The digital transformation and the introduction of tablets and smartphones pursue this objective.
The digital equipment might be difficult to use by field inspectors or quality controllers to complete their checklists and forms in real-time: hands are busy, tablets are heavy, smartphones too small.
SPIX industry introduces SpixForCheck a breakthrough solution dedicated to inspectors and quality controllers to help them in their digital interactions while working on the field. The key added value of SpixForCheck with its NoTouch-NoScreen voice interface consists in:
- keeping the hands of the operator free,
- release the constraints of looking at a small screen,
- avoid carrying a digital equipment,
- enable to complete forms and checklists in real-time,
- without any compromise with the operator’s safety.
For the first time with SpixForCheck and its NoTouch-NoScreen voice interface, the constraint of the digital screen is removed. Field operators can complete checklists and forms by voice in real-time, hence drastically improving the quality of the collected data. They can keep their hands free, hence improving their safety at work.
Press contacts
André JOLY – Managing Director
Phone. : +33 (0)6 25 17 27 94
Email: andre.joly@spix-industry.com
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“Voice Experience”, “SPIX” and “SPIX industry” are registered trademarks of Simsoft3D SAS.