The holy grail of manufacturing is simple to define but difficult to sustain: minimize variation and run to target. Quality Window 6 introduces a powerful new way to support this — with real-time alarms and email notifications that make your processes more responsive and consistent.
Why Variation Matters
Low variation means your customers get the same product every time — no surprises, no complaints, no waste. This is essential whether you’re producing car parts, converting raw materials into diapers, or manufacturing foods that need to look full on a shelf.
Take fill weights as an example. A container that’s technically in spec but visually underfilled may be perceived by the customer as short-changed. That’s a loss in perceived value. On the other hand, overfilling increases raw material usage and shipping costs. Either way, if you’re not running to target, you’re paying for it.
Alarms: Your Quality Control Center
In QW6, the old Rule Violation Summary has been replaced by the Alarms screen. This is your new center for exception management. When data is entered into a QW application and violates a rule:
- An alarm is automatically triggered
- The violation is logged in the Alarms screen
- The operator is prompted to acknowledge the issue
- Optionally, an email notification is sent to stakeholders
This change helps teams respond faster and stay focused on active issues. It’s not just about flagging problems — it’s about creating a repeatable, traceable response process.
Email Notifications in QW6
With Quality Window 6.1 or later, you can configure the software to automatically email notifications when specific rules are violated. These notifications are customizable, triggered only for the rules you care about, and routed to the right recipients.
To use this feature, you’ll need:
- A working mail server (SMTP) and credentials
- A distribution list or email group to simplify rule management
- QW Admin access to configure rules and applications
Each email can include details like the variable, value, rule description, timestamp, and user who entered the data. This ensures that the right people know about the right issues, in real time.
Best Practices for Reducing Variation
Start by identifying the process variables that matter most. Organize them by line, product, or customer and define appropriate process limits:
- Specification limits (LSL and USL)
- Control limits (LCL and UCL)
- Target values
Next, determine how often you need to sample these variables. The rule of thumb is: how long can this variable go unchecked before it causes trouble?
Then, apply control rules and define which ones should trigger alarms and/or email notifications. Use different rules depending on what you’re trying to detect — one-sided limits, trends, or shifts. Don’t overload your team with noise; configure alerts for real issues that require action.
Add variable-specific user help if possible. You can share guidance or troubleshooting steps to help operators respond quickly — and consistently — when alarms occur.
Investigate, Act, and Improve
Once an alarm is triggered:
- Review it in the Alarms screen and acknowledge it
- Use the Control Chart to view trends, histograms, and summary statistics
- Explore variable relationships to identify potential causes
- Compare performance before and after interventions
- Review snapshot reports for broader process insights
The final and often overlooked step is to adapt. If you discover a previously unmonitored variable is driving the issue, use QW Admin to add it. Start monitoring it right away. This closes the loop and prevents future surprises.
Reporting and Accountability
Every alarm and acknowledgment is logged. The Alarm Report allows you to:
- Review past alarms and user responses
- Export to Excel for sharing or compliance
- Analyze frequency and root causes over time
This creates transparency, supports audits, and gives your quality team the data they need to continuously improve.
Built for Change
Quality Window isn’t just a monitoring tool — it’s a system for operational discipline. It’s built for shop-floor users who need quick answers and easy adjustments. You don’t need to wait for IT. You can make changes today and see results in your next sample.
Whether you call it SPC, centerlining, or process control, QW6 provides the tools to minimize variation, hold the line on quality, and drive to target — with alarms, notifications, and easy-to-use investigation tools at the heart of it all.