Plex Online provides a full suite of Quality Management tools. Quality is a major strength area for Plex. Whether the
quality modules are used stand-alone, connected with a legacy ERP system, or as part of the fully-integrated Plex Online enterprise
system, Plex Online is recognized as having a best-in-class quality solution.
The Plex 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.
Plex 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.
Plex Online is the only system on the market today that interconnects engineering, quality, and manufacturing. Plex 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.
Plex 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 Plex Quality Management System provides a
comprehensive quality solution.
Features: (Click [+] or [-] to expand/collapse a feature.)
Core Quality and 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. Plex 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. Plex Online handles BOMs with just a
few components, or many thousands.
CAD Integration
Plex 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 Plex 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 Plex 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 Plex 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 Plex 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 Plex and then easily create hyperlinks from the shapes within the diagram
to various capabilities within Plex, such as other Plex 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 interactive Business Process
Flow Diagrams for TS-16949; the fully power of Plex becomes available at your fingertips, directly from the flowchart itself. Auditors
love it. This module is also suitable for providing Plex-integrated interactivity to any other type of Visio diagrams.
Internal and 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.
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