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AQP-PARTS:
Advanced Quality Planning System
For Sheet Metal Parts
March 2003
 | Advanced Quality Planning Process For Sheet Metal Parts |
The automotive and appliance sheet metal parts process progresses from conception to production in a series of steps that include Part Design, Material Selection, Tool Design, Tool Tryout, and Part Production Launch. To supply quality products and technical support, a material supplier is involved in the early stages of Part Development, a process known as Early Vendor Involvement (EVI).
Suppliers typically document the performance of the supplied material and the stamping tool for each part included in the EVI program. Detailed reports are then sent to the customer that identify the essential components and key results of each tool trial. Suppliers typically rely on Forming Limit Diagrams (FLD) to quantify these results.
Once a part is in production, suppliers continue to evaluate the stamping process using FLD and similar analytical tools. When problems arise in the production of a part, suppliers and stamping plant personnel typically review pre-production tool trial reports to provide an insight on the problems that were overcome during the early stages of the part's development. This historical referencing is necessary to provide quick and proper corrective actions that are critical during the production phase.
The Advanced Quality Planning process for sheet metal parts addresses the supplier and customer requirements during part development and part production by implementing standardized procedures, analyses and documentation. By maintaining quality and customer support at the highest level during the EVI process, and by providing consistency in applying the procedures and satisfying documentation requirements, continuous improvement is ensured throughout the production cycle.
The Advanced Quality Planning Process
requirements during Part Pre-Production & Production
include:
DEI recognized the importance of computerizing the Advanced
Quality Planning Process to create an Advanced Quality Planning System for
suppliers and customers – the result of which is AQP-Parts.
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AQP-Parts is
a Computerized Advanced Quality Planning System for Sheet Metal Parts
developed by DEI primarily for material suppliers but also for tool shops,
stamping plants, and customers.
AQP-Parts computerizes
the processes and documentation requirements needed for supporting Part
Production and Tooling Development for automotive sheet metal parts.
AQP-Parts is
a user-friendly quality control system that provides comprehensive part
tracking, FLD and Small Strain analyses, and standardized reports for office
and mobile users. The System is structured to allow users to follow the
Advanced Quality Planning Procedures (Guidelines) to consistently record and
document critical Customer, Program and Part information into the
comprehensive Part Tracking Database.
AQP-Parts stores
detailed Part Information including Part Blank (and Tailored Blanks)
dimensions and material properties, Customer Specifications, and Program
Production Volumes. Part Development progresses though a series of Tool
Tryouts also referred to as Tool Trials.
AQP-Parts documents
each Tool Trial with standardized Tool Trial Reports to the customer
documenting critical information including Part, Blank, Tool Shop, Press
Parameter, Material Property, Part Image and Strain Analysis Data. Utilities
such as the Material Production Capability Database and the Advanced Strain
Analysis calculations simplify Tool Trial Report generation. The consistent
documentation of the ongoing Part Tool Trials enables a material supplier to
maintain a complete Part History within the Tool Trial Reports.
AQP-Parts provides
Management Reports that summarize Part information at the Program,
Production Location, or Customer level. Log Reports provide the necessary
details for all key activities logged while using the System.
AQP-Parts is
a key component of a material supplier's Early Vendor Involvement program
and provides continuous monitoring and control during Part Development,
Pre-Production, Production and Post-Production.
AQP-Parts standardizes Documentation and Reporting
Methods by providing:
AQP-Parts standardizes procedures for Part
Pre-Production and Production Support by providing:
| Automated Procedures (Guidelines) |
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| Customer & Supplier Dependent Selections |
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| Comprehensive Part Tracking |
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| Supplier Material Property Data Interfaces |
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| Remote Access From Mobile Users |
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| Material Property Selection |
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| Automated Activity Log Entries |
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AQP-Parts also includes tools for assisting in program
planning, as well as diagnostic and database management tools.
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| AQP-Parts Features |
AQP-Parts includes the following features:
| Intuitive User Interface
AQP-Parts operates interactively and is controlled by a series of menus and popup windows easily accessible by keystroke or mouse. Screen specific features provide additional controls with detailed help screens only a keystroke away. General and Engineering-specific error checking of keyboard entries eliminates erroneous input entries. Tabbed dialog windows provide a well-organized system of presenting several screens of information in a single window.
Key features of the User Interface include an 'Explorer' tree style control that allows easy selection of Part and Tool Trial information sorted by Customer, Production Location, and Program. Smart icons identify the program status (pre-production, production, or inactive) of each program, the part status (pre-production, production, or inactive) of each program's part, the trial status of each part's trial (pre-production or production), and the report status (draft or final) of each trial's report. Right click options provide additional controls and ease of use. |
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AQP-Parts data entry is simplified through the use of selection
lists for various input fields. These lists help maintain input accuracy and
consistency. The types of selection lists used in the System include:
| Fixed List - Limits data input to items on a predefined drop-down list. |
| Standard Combination List - Allows data input either by typing text or
by selection from a predefined drop-down list. |
| Maintained Combination List - Same as the Standard Combination List with
one addition, any entered text will be added to the selection list for
future use. |
| Enhanced Selection Lists - Allows data input from a combination of
selection list inputs. |
AQP-Parts is a 32 bit application for use on Windows
95/98/2000 and Windows NT operating systems. AQP-Parts
is Year 2000 (Y2K)
Compliant.
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to AQP-Parts Features
| Comprehensive Part Tracking Database
AQP-Parts features a robust relational database of more than 500 data fields logically grouped in over 30 related tables for documenting and tracking parts from development through production. The database stores all aspects of a part's history including Customer, Production Location, Program, Part and Trial information. This hierarchy maintains consistent information and provides default values from the Customer level down to the Trial Information level. All Tool Trial details are stored in the database to generate comprehensive Tool Trial Reports.
A Key feature of the database is the tracking of Tailor Welded Blanks, where a part blank is comprised of several steel blanks welded together prior to stamping. In these cases, the database will track the details for each subassembly of the Tailored Blank. |
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Features
| Flexible Part Data Synchronization And Data
Exchange
| AQP-Parts provides synchronization and data exchange options for both office and mobile users. Network and dial-up synchronization provides users the option to enter data off site and then synchronize with the central database, as needed. A partial data exchange option is provided to allow the exchange of relevant data based on a user's assigned responsibilities. This minimizes synchronization time, local database size and potential data conflicts. Data exchange and database synchronization is simplified through the use of a tree style control to graphically display and select the contents of the master and local data files. Trial import and export features provide additional flexibility for mobile users. |
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AQP-Parts Features
| Part Definition and Control
AQP-Parts provides comprehensive program and part definition. Program data is entered in an organized tabbed window where the sub-tabs are
Data, Default, Volumes and
Log. Part data is entered on sub-tabs Data, Definition, Blanks
and Log. Critical fields are protected from modification by unauthorized personnel.
Key features include the definition of default units and analysis options for all trials in a program. Part definition encompases Tailored Blanks and includes the option to define FLDo for a range of n values. Project logs record all activities at the Customer, Program, Part, and Trial level. |
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AQP-Parts Features
| Detailed Tool Trial Documentation And
Reporting
AQP-Parts provides a user-friendly interface for users to record detailed information about a Tool Trial. A Tool Trial is an integral piece of the complete part history. Tool Trial documentation provides a snapshot of all Part details as the tool is being evaluated at the trial. A Tool Trial can track a single blank part or a Tailored Blank part consisting of multiple (up to eight) blanks. Tool Trial information is entered in an organized window where the main areas are
Part, Trial, Blank(s), Images, Attachments, and Report.
 | The Part Tab
The Part
Tab displays general Part Information including the
customer, production location, program name, part name, part
number, vehicle line, and make, model and styles.
A Key feature on the Part Tab includes the Update Key Trial Data
button whicch updates selected trial data to reflect current
customer, program, and part data. |
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| The Trial Tab
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Trial Tab provides an area for the input and
display of the Trial data. The Trial tab contains
sub-tabs for Trial Information, Press Identification and Lubrication,
Press Binder/Ram, and general Trial Notes. Refer to
the User’s Manual for a description of all fields on these
sub-tabs.
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| The Blank(s) Tab
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Blank(s) Tab provides access to a specific part
blank, where, in a Tailor Welded Blank, there are multiple blanks
per part. Each Blank tab provides an area for the input and
display of the blank data through sub-tabs for Material,
Strain, and Small Strain. The Blank(s) tab and
sub-tabs provide for material and strain data input for a tool
trial, automated strain calculations and FLD generation, and
numerical and graphical results viewing. |
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 | The Blank(s)/Material sub-tab
provides for the input and display of each blank’s Material data.
The Blank(s)/Material sub-tab main areas are for Trial
Material, Mechanical Properties, Surface Properties, and Chemical
Composition.
Key features on the Blank(s)/Material sub-tabs include the
Production Capability Graphical Comparison and Update Range features
on the Blank(s)/Materia/Mechanical Properties sub-tab. Refer to
the User’s Manual for a description of all fields on these subtabs.
Notes:
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Production Capability Ranges on
the Blank(s)/Material/Mechanical Properties sub-tab are based on
the Customer and Measured Thickness, Product, Quality and Quality Grade
values from the Blank(s)/Material/Trial Material sub-tab.
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Measured Thickness (and
Measured Thickness units) on the Blank(s)/Material/Trial Material
sub-tab is also used as the default value for the Blank Thickness field
on the Blank(s)/Strain/Data sub-tab and the Reference FLD
Measured Thickness field on the Blank(s)/Strain/Options sub-tab.
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Specified Thickness on the Blank(s)/Material/Trial
Material sub-tab is used as a default value for the Reference FLD
Min or Specified Thickness field on the Blank(s)/Strain/Options
sub-tab.
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The Longitudinal Actual n Value
on the Blank(s)/Material/Mechanical Properties sub-tab is used as
the default value for the Reference FLD Specified or Measured n Value
field on the Blank(s)/Strain/Options sub-tab.
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The Longitudinal Lower n Value
on the Blank(s)/Material/Mechanical Properties sub-tab is used as
the default value for the Reference FLD Min n Value field on the Blank(s)/Strain/Options
sub-tab.
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The Total Elongation Transverse
Actual field on the Blank(s)/Material/Mechanical Properties
sub-tab is used as the default value for use in Library FLD curves (that
are based on Total Elongation) on the Blank(s)/Strain/Options
sub-tab. |
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| The
Blank(s)/Strain sub-tab provides an area for the input
and display of each blank’s strain analysis data. The Blank(s)/Strain
sub-tab main areas are for Data (circle grid and/or thickness
strain) and Options (analysis and reporting).
Key features on the Blank(s)/Strain
sub-tab include multi-option strain input, advanced FLD analysis
options, flexible reporting options, and activating the FLD
analyses and graphical results display. |
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Since the Blank(s)/Strain
sub-tab is one of the most important areas in AQP-Parts, more
information on the features and fields of this sub-tab are provided in
the Notes that follow.
Refer to the User’s Manual for a
description of all fields on these subtabs.
Notes:
| Strain data entry is provided for up
to 25 data points for the part or the addendum. |
| Flexible strain data input can
utilize either or both methods of strain data input:
| % Major Strain and % Minor Strain |
| Thickness and % Minor Strain |
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| FLD curves can be based on Blank
Thickness or user-specified thickness. |
| Selectable Marginal Zone is provided
for both the part (0% to 25%) and the addendum (25% to 25%). |
| Split tracking is provided for the
part, addendum and binder. |
| FLD option can replace the standard
FLD curve with an approved FLD curve from the AQP FLD library. |
| FLD options can include in the
analysis graph a Reference FLD curve based on minimum, specified,
measured or other value of thickness and n Value. |
| Report option can combine or separate
the Circle Grid and Thickness Strain points. |
| Report option can exclude the graphs
for FLD, % Thinning, or the Thickness Strain. |
| Viewing option of analysis results is
provided without previewing the entire report. |
| Viewing option for Tailored blanks
can display results of a single blank or of all blanks. |
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The Blank(s)/Small
Strain sub-tab provides an area for the input and display of
the Small Strain analysis data. The Blank(s)/Small Strain
sub-tab main areas are for Data, analysis Options, and a digital
Image.
Key features on the Blank(s)/Small Strain sub-tab include
the option to enter data as Major and Minor strains, or as
strains measured along the 0º, 45º, 90º, and 135º reference
angles. |
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| The Images Tab provides an
area for the input and display of digital Image data. The Images
tab contains sub-tabs for up to four (4) separate digital images for use
in the Tool Trial Report. Images can be either half-height or full page
size. More than twenty formats are supported including JPG, PCD, BMP, TIF,
and WMF. |
| The Attachments Tab provides
an area for the input and display of graphical data as an Attachment to
the report. The Attachments tab contains sub-tabs for up to
four (4) separate Attachment graphics for use in the Tool Trial Report.
Images are full page size. More than twenty formats are supported
including JPG, PCD, BMP, TIF, and WMF. |
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The Report
Tab provides an area for the input and display of the Tool Trial
Report details. The Report tab contains sub-tabs for
Report Identification, Distribution Lists, Report Contents,
Report Comments, Report Purpose, and Report Recommendations.
Key features on the Report tab include the option to
specify the general report contents and blank-specific analysis
results. |
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Features
| Material Specification And Production
Capability Comparison Database |
AQP-Parts
handles detailed material information for each
part blank. During a Tool Trial, material specifications, mechanical
properties (in all three directions), surface properties, and chemical
composition are documented. The System provides an interactive Material
Property Range or Production Capability Comparison Database. Based on the
material specification and thickness, a comparison is generated for the
material properties specified for the longitudinal, transverse and diagonal
directions, and is included in the Tool Trial Report.
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AQP-Parts Features
| FLD And Enhanced Strain Analysis Features And
Calculations
| AQP-Parts
provides comprehensive Circle
Grid and Thickness Strain analyses that address all aspects of the
various automotive manufacturer requirements. Forming Limit Diagrams (FLD)
and Thickness Strain Charts are based on the circle grid and thickness
strain data, respectively. Data points can be specified as being
located on the part or addendum. Separate Forming Limit Diagrams,
Thickness Strain Charts, and % Thinning Charts are produced for each
part blank and addendum. Reference FLD Curves, Library FLD curves, and
FLD Marginal Zones can be specified within the System. An overall Part
Status of Safe, Marginal, Failure or Wrinkling and a % Major Strain
Safety Factor will be calculated for the Tool Trial Report for single
blank parts and tailored blank parts. |
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AQP-Parts Features
| Enhanced Small Strain Analysis Features And
Calculations
| AQP-Parts
also provides for Small Strain analysis in addition to the standard
Circle Grid and Thickness Strain FLD Analyses. The Small Strain
Analysis is based on circle grid strains along associated reference
angles (0º, 45º, 90º, and 135º). Uniform and multiple circle grid
diameters are permitted. Meaningful results are provided through
numerical averaging and graphical display options. |
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AQP-Parts Features
| Industry Standard Tool Trial Reports
| AQP-Parts
produces standardized Tool Trial Reports
based on entered part and trial data. Reports provide detailed trial
observations, strain analyses, conclusions and recommendations. Digital
images can be incorporated into the Trial Report to highlight the part,
part drawings, or problem areas. Report Attachments and user specified
options provide flexible reporting within a standardized environment.
Reports can be printed or sent electronically in Adobe Acrobat PDF
format. |
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AQP-Parts Features
| Flexible Part History Reporting Features |
AQP-Parts provides management reports summarizing Part Severity Ranking, Program Material Volumes and Advanced Product Quality Planning. Additional reports include summaries for Material Forecasts, Program Log, Parts List Report, and customer-specific reports. Data export options provide unlimited report capabilities and can be customized to individual management requirements. Key data fields can be exported to a spreadsheet for pivot table generation and further analysis or sent electronically to centralized systems such as Ford's FLD Report Summary and Supplier Information Reporting System (SIRS).
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Features
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to AQP-Parts Features
| Quality Control Tools For Data Consistency And
Data Integrity |
The AQP-Parts System is a Quality
Control Tool. It is to be used to maintain Quality and provide feedback for
Continuous Improvement during the Part Development and Part Production
cycles. Standardized reporting options and ease of data availability
contribute to its effectiveness.
Multiple levels of quality control are also
maintained within the System itself. Quality is initiated with the
centralized database and maintained through logical controls. Standardized
input selection lists, consistent unit usage, automated calculations, error
checking and warning systems, standardized reports, manual and automatic
program log entries, cross linked checklists and guidelines, all contribute
to the data consistency and integrity needed to maintain a high standard of
quality.
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AQP-Parts Features
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| AQP-Parts Cost Savings Benefits |
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Greater Process
Up-Time
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Problem parts are resolved quicker by reducing the time for trial evaluation and report generation.
Cost Savings: Thousands of dollars for each problem part by restarting the presses sooner.
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Accurate data analysis and evaluation will improve the success rate of proposed process modifications.
Cost Savings: Thousands of dollars if identifying a part to be safe that may otherwise have failed.
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Since it will be quicker to perform the FLD analysis and report generation, there will be much more time to do additional trials and process evaluations of other parts.
Cost Savings: Thousands of dollars if preventing an unanticipated failure.
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| Reducing the evaluation and report generation time may reduce overall staff requirements.
Cost Savings: Thousands of dollars annually, depending on the staff reduction. |
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Improved Process
Documentation
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The AQP-Parts relational database records all essential part information and process conditions. |
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Hardcopy reports include all recorded trial data and analyses. |
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Automated summary reports from the database provide historical comparisons of key process parameters. |
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Tailor Welded Blanks' are fully documented in the database and reports. |
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The automated procedures and documentation in AQP-Parts fully address QS 9000 requirements. |
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Increased Analysis
Capability
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FLD data input can be % major and % minor strain, or thickness and % minor strain. |
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Strain analyses includes the standard FLD, Thickness Stain and Surface Strain analysis. |
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Analysis options include a Reference FLD curve, Library FLD curves, Maximum Thinning Limits, and Buyoff FLDo based on direct entry of FLDo or as a function of n Values. |
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Constant Volume analysis ensures accurate data entry and strain analysis. |
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Automated strain status calculations provide accurate status and safety margins. |
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Automated summary reports provide the data for continuous improvements and process optimizations. |
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Networked, Synchronized, and Mobile editions of AQP-Parts address all possible user configurations. |
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Reduced Investigation/Report Generation
Time
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The automated FLD analysis can be performed in minutes with the click of a button. |
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The specific analysis and reporting requirements of GM, Ford, and DCX are fully automated. |
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Reports are generated in seconds in standardized report formats. |
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The AQP-Parts menu driven software with tabbed and sub-tabbed groupings makes it quicker to locate and record process data. |
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The database provides access to the complete part history, which is essential when analyzing problem parts. |
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Improved Report
Understanding
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Reports include all entered data and analysis results clearly labeled. |
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Pre-formatted reports are consistent and easy-to-read. |
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Standardized input selection lists ensures report consistency. |
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Summary Reports and Pivot Table spreadsheet reports provide superior management tools. |
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Automated Error
Checking
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Quality Control is provided by standardized selection lists, automated constant volume checks, and Engineering-specific error checks. |
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