Quality Management Software

Plexus Online provides a full suite of Quality Management tools. Quality is a major strength area for Plexus. Whether the quality modules are used stand-alone, connected with a legacy ERP system, or as part of the fully-integrated Plexus Online enterprise system, Plexus Online is recognized as having a best-in-class quality solution.

The Plexus Online quality solution has been designed for manufacturers who need to continuously improve quality, achieve real-world benefits, and maintain compliance with quality standards (ISO, QS-9000, TS-16949, AS-9100, etc.) using limited labor resources.

Plexus Online is not just a documentation system to impress the auditors (although it does that in spades!). It's designed to provide real, measurable benefit to the manufacturing effort in the form of increased process repeatability, reduced variation, increased production throughput and reduced defects.

Plexus Online is the only system on the market today that interconnects engineering, quality, and manufacturing. Plexus provides an automatic, paperless and real-time linkage between the Part Dimensions, FMEA, Control plan, Process Instructions, Checksheets, Inspection Data Collection and SPC, along with Part Layouts, PPAPs, Gage Studies, and Capability Studies.

Plexus Online is also well known for providing the best Problem Control System in the industry. Used by many major Tier 1 companies, this subsystem is used to manage Corrective Action Reports, Customer Concerns, Online Supplier Management, 8D Problem Solving, and many other types of problems.

Consisting of over interrelated 40 modules, the Plexus Quality Management System provides a comprehensive quality solution. Here is a list of some of Plexus Online's quality modules:

Core Quality & Document Authoring

  • Part List
    This module provides a master list of Parts, including all associated part data, such as Part Description, Part Type, and Revision. This modules also provides an easy-to-use mechanism to upload small digital photos of each part. The Part List also provides links to many other areas of the system, where applicable, such as Key Part Dates, Customer Part Numbers, APQP Checklist, Inventory, Shipment History, Problem History and so on.

  • Process Routings
    A process routing is the series of steps required to manufacture or process a given part. This module defines those steps. Includes the Operation Number, Operation Name, Approved Workcenters and Suppliers, Crew Size, Weight, Container Type, and other key routing data.


  • Bill of Materials
    This module defines the components that make up a part. Plexus Online supports infinite levels of BOM. It provides indented BOM, exploded BOM, drilldown BOM, and a variety of other methods for visualizing and editing BOMs. Plexus Online handles BOMs with just a few components, or many thousands.

  • CAD Integration
    Plexus provides a special feature within your CAD system to number and name each Dimension on the Part Drawing. Then, whenever the drawing is saved, it synchronizes the dimensions and their tolerances to the Part Specification List in Plexus Online, which in turn drives the Control Plan, Checksheet, and data collection systems. The CAD Integration subsystem saves you from having to type dimensional data into Plexus and adds a high-degree of advanced integration between Engineering, Quality and Manufacturing. Currently in use with AutoCAD 2004. Will also work with other CAD systems such as SolidWorks, CATIA, Unigraphics, Pro/Engineering, and so on.


  • Part Specifications
    This module is used to establish and maintain a detailed list of dimensions and characteristics on specific parts, including Dimension Name, Target Value and Tolerance.
  • Process Flow Charts
    An extended capability for creating industry-standard, presentation-quality Process Flow diagrams that are driven from the part's Process Routing.

  • FMEA
    The Failure Mode & Effects Analysis module provides the ability to create, edit and view QS-9000-compliant FMEA's on screen, including Design and Process FMEA's. FMEA's are developed at the beginning of the project to address the following questions: 'What can go wrong? What will happen if it does? What controls do we have in place to detect it if it does? How should we improve the part or process?' Some companies use 'Common FMEAs' that cover a whole range of processes in a generic fashion. Other companies establish one or more FMEA's for each part. FMEA's are a requirement of QS-9000.

  • Control Plans
    The Control Plan module provides the ability to create, edit and view Control Plans and detailed Inspection Instructions on screen. Some companies create one or more "Common Control Plans" to cover a whole range of processes in a generic fashion. Other companies establish a detailed Control Plan, breaking down each dimensional Specification at each operation. Control Plans include the Sample Frequency, Gage, type of Control chart, and other quality-oriented data. Control Plans are a requirement of QS/ISO-9000. The Control Plan is highly integrated with the Part Specification system.

  • Dynamic Control Plans
    The Dynamic Control Plan module combines the benefits of specification-level Control Plans with the Process FMEA methodology, Gage R&R, and Cp/Cpk. DCP's are a requirement of AIAG/Ford.

  • Checksheets & Process Instructions
    Powerful subsystem for authoring process instructions and checksheets. Fully integrated with and driven from the Control Plan system.

  • Inspection Data Collection
    An extension of the Checksheet system that allows the user to enter inspection data directly into the onscreen Checksheet, validate it against the spec limits, and store that data in the Plexus Online database.

  • SPC
    This module provides the ability to collect in-process inspection data and to conduct Statistical Process Control. It also handles Capability Studies, Dock Audits, Part Layouts, Final Inspection Sheets, PPAP Inspections, and Special user-defined checks. It performs all statistical calculations such as standard deviation and Cpk and it prints a variety of charts, such as Histogram, Average and Range, Run Chart, Individuals Chart and more. This system is highly integrated with the Part Specification, Control Plan, and Gage Control Modules. SPC is generally a requirement of ISO/QS-9000. As an alternative to traditional software, there are an increasing number of SPC systems available through the Internet. They range from simple Control Charting utilities to comprehensive quality solutions. The Plexus Online system integrates all aspects of managing quality, including full continuity between the Part Characteristics, FMEA, Control Plan, Process Instructions, Inspection Checksheets, and SPC Control Charting. Once the user sets up the Control Plan, the system uses that data to automatically create the Inspection Checksheets, and drive Control Charts. This establishes a seamless link from the part characteristic, through the ISO quality documents, and to all inspection data. The system also provides modules for Gage Control, Corrective Action, APQP Tracking, Supplier Quality Management, and many other areas.

Other Quality Modules

  • Problem Control
    Also known as Problem Reporting and Resolution (PR/R), Corrective Action, Customer Concern Log, and a variety of other names. This module is used to record, track, follow-up on, resolve and report upon problems and concerns within the company. It includes forms for the 8-Disciplines of Problem Solving, Corrective Action, Supplier PR/R, Customer Concern, and more. This module provides the ability to assign one or more actions for Containment, Correction, and Prevention of problems. Problem Control is a requirement of ISO/QS-9000. This system is often used in E-Communication, to assign problems to suppliers, who then use the system online to respond to those problems.

  • Cost Recovery
    This module, which is usually used in conjunction with the Problem Control System, is used to issue and track charge backs to suppliers when problems occur.

  • Issue Management
    A simple-to-use system for recording and maintaining focus on issues within the company.

  • Five Why
    This module supports the Five Why Problem Solving methodology. It is highly integrated with the comprehensive Problem Control System.

  • Document Control System
    The Document Control module provides the ability to store, edit, track and view documents on line. Includes full electronic approval and revision tracking system ideal for ISO/TS 16949. Supports many file types, including Word, Excel, Powerpoint, AutoCAD, PDF, HTML, and more. This module is usually used to control the Quality Manual, Procedures and Work Instructions. It is also used for the Employee Handbook, Supplier Handbook, and Technical Documentation.

  • Specification Management (Documents)
    The specification module is used for managing and tracking Specification Documents, such as Engineering Specifications (E.S.), Material Specifications, and other external standards documents.


  • Compliance Module (TS-16949, ISO, AS9100)
    The Compliance Module provides a flexible, user-configurable methodology for a company to assure compliance to one or more standards such as TS-16949, QS-9000, Sarbanes-Oxley, AS9100, etc. It provides a structure for documenting the standard, and then a formalized mechanism for review/signoff, audits, checklists, procedures, documentation, and follow-up activities.

  • Visio Integration (Flowcharts/Diagrams)
    This module allows you to upload a Visio Diagram into Plexus and then easily create hyperlinks from the shapes within the diagram to various capabilities within Plexus, such as other Plexus modules and procedures/documents in the Document Control System. You can also configure the shapes to drill down into other flowcharts or out to external web pages. The fully-annotated Visio diagram is displayed to users in a simple-to-use user interface (no Visio license required). This module is ideal for providing intefactive Business Process Flow Diagrams for TS-16949; the fully power of Plexus becomes available at your fingertips, directly from the flowchart itself. Auditors love it. This module is also suitable for providing Plexus-integrated interactivity to any other type of Visio diagrams.

  • Internal & Supplier Auditing
    This module provide the ability for the user to define, track and conduct audits, both internally and for suppliers. Generally, this module is used to meet ISO/QS-9000 requirements, although, because the audit forms are user-definable, it can also be used for a variety of other auditing/checking tasks.

  • Gage Control
    This module provides a comprehensive set of tools for managing and control measurement gages within a company. Based on a Master Gage List, each gage is serialized and bar coded. The system handles Gage Calibration, Calibration Scheduling, calibration priority reports and automatic email notification when gages are due for Calibration. It also includes a powerful Gage Study system, including Repeatability, Reproducibility (GR/R), Bias, Linearity, and Stability. The Gage Control System was designed based on the AIAG's Measurement Systems Analysis (Third Edition). The Gage Control System is integrated with the Control Chart and SPC systems.