Case Studies

CASE STUDY - NOV Rig Systems

March 8, 2017

The Customer's Business

NOV Rig systems has a long history of manufacturing advanced drilling equipment packages. It constantly working to solve operational challenges, evolve its products, minimize the customer risk and improve the performance of drilling operations around the world.

NOV creates various parts for the Oil and Gas drilling equipment and each part's drawing contains hundreds (300-400) of dimensions and GD&T items. As its business is continuously growing, few years ago NOV engaged with an Inspection software vendor to improve its in-house Quality Manufacturing productivity and deployed their product. While some automation was gained, NOV continued to face major challenges even after deploying that software. This challenges prevented NOV from evolving to the next level of productivity and achieving its operational goals of Quality Manufacturing.

The Need for a Solution

The following are some of the key challenges NOV still encountered even-though it was already using a dedicated software product. Some of the challenges were:

  • Ballooning OCR was slow and read the dimensions one at a time, no automated GD&T extraction
  • No database attached, only saving things in the file system. This made searches, reporting and access to the information not intuitive and slow. Especially the consolidation of documentation per project was taking a long time and was error prone.
  • Key functions such as re-numbering and managing revisions were not strong enough

The Decision Process

NOV Rig Systems was looking around for an automated, more advanced, solution and found HighQA with its product "Inspection Manager". After a 45 minutes web session it was clear to the team (quality, inspection and manufacturing staff) that the potential in this product can improve on the current challenges. After additional one month of having a trial version locally installed and a short training, the team at NOV concluded to adopt the Inspection Manager product and partner with HighQA.

During their trial month and decision making process the team at NOV looked specifically for the following things:

  • How long HighQA in business and the maturity of the Inspection manager software (coming up now on version 4.5 in 2017)
  • Software ease-of-use and intuitive navigation
  • Advanced level of seamless, unattended, automation (such as reading automatically CMM inspection results from a network folder)
  • Inter-operability with other software packages (SPC, ERP, etc.)
  • Overall productivity increase (between full OCR, automation and good data schema that supports NOV's business processes)
  • Partnership with HighQA as a vendor - responsiveness, technical support team knowledge, ease of implementation
  • HighQA vision and road map evolving to become a leader in the Quality Manufacturing software and longer term bringing more stake holders into the loop with a supply chain software platform

The Implementation

The overall on-boarding process and experience was very good. Within 30 days the system was up and running, staff were trained, manufacturing and inspection were fully in alignment, the software was installed on the server with a centralized database (client/server configuration) and adoption was smooth.

Using a floating license configuration allows multiple users to access the software and the overall productivity increased significantly. The software is functioning above and beyond and the team at HighQA is highly responsive to various enhancements requests as well.

    "Working with Inspection Manager has enabled us to streamline our methods of inspection from First Article to production Runs. It has transformed our inspection business process, it has improved our quality, productivity and efficiency."

Sergio Zavala - Inspection Supervisor

National Oilwell Varco | NOV Rig Systems (Orange, CA)

CASE STUDY - HyPro Incorporated

September 4, 2018

The Customer's Business - Improving Management Processes Through the use of Quality Software

HyPro Inc. is a provider of machined components and assembly solutions. Hypro Inc.'s goal was to improve its quality management processes, ranging from ballooning, GD&T recognition, through inspection planning, CMM and inspected data collection and final documentation and reporting. As such, it contacted HighQA, the software company behind the Inspection Manager Software, and after conducting a professional due-diligence, it decided to join High QA’s community of customers.

While using a different software product, HyPro Inc. realized they needed to make a change. They felt staff still spent too much time on manual tasks that could be automated, and the then current software didn’t lead HyPro Inc. to adopt new and better practices.

To share one example, says Tyler Schildt, Hypro Inc. lead quality engineer, we do a lot of “big things.” It can be more than a thousand dimensions and GD&T characteristics. Ballooning took so much time that the CMM team already completed their inspection prior to having the ballooned plan shared with them. Productivity and internal alignment didn’t improve much with the software and HyPro Inc. was looking to “do things different.

"With the Inspection Manager Software, HyPro Inc. tested and confirmed that complex tasks that took previously five days to accomplish, can be done now in half a day to a day.

How deploying a modern Quality 4.0 software applications “completely changed our business," as told by Tyler Schildt, Hypro Inc. lead quality engineer.

Call it an expert system, or artificial intelligence—we looked for software that with one-click, can scan/OCR balloon and extract, with high accuracy, all the dimensions and characteristics from a 2D drawing.

Database-driven and strong IT infrastructure—we work in collaboration with seven different facilities, so we need all of the data to reside in one place and be accessed by 20-30 staff concurrently. We need it to be backed up daily to our remote back up location.

Performance should be optimized—trying a cloud solution did demonstrate some benefits on the IT side, but not when it comes to performance. If you are working on a loaded drawing and make one simple mistake, it can cost you 15 minutes waiting for the screen to refresh. We wanted a more robust and sophisticated architecture that will allow us the best of both.

Streamline our quality management process—We wanted to have the CMM inspection driven by an inspection plan that was initiated by the software, so all ballooned characteristics are aligned. Once we have the collected data, we can create all the documentation and reporting (i.e. PPAP) in a click of a button and re-run it as many times we need.

Usability and level of service—being in the 21st century, we want software that is highly intuitive and usable, one that takes you through your work activities in a natural way. The ability to self-train and access a highly responsive service support on the vendor side was a big plus for us.

         "With the help of HighQA and the Inspection Manager software, we were able to accomplish all the above and more. As we now experience higher demand, we are able to accommodate it with the current staff and deliver better quality products on time. We are excited about the growth possibilities partnering with High QA."

Tyler Schildt - Lead QA Engineer

HyPro Incorporated (Waterford, WI)

Company News

About High QA, Inc.

Committed to the automation of quality assurance processes, High QA is a team of manufacturing experts with over 100 years of experience in mechanical CAD/CAM, inspection, PLM and Lean manufacturing.

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