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Process Quality Manager: monitoring and documenting process data

ConnectedManufacturing Bosch Software Innovations Process Quality Manager
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Industry 4.0 process data monitoring in the cloud - even for SMEs

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Industry 4.0 Tightening Software in the Cloud

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Industry 4.0 software solution for tightening experts

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Brochure Process Quality Manager

Brochure Process Quality Manager

Joint solution of
Bosch Rexroth & Software Innovations – tightening & software expertise brought together.

Managing process data - the intelligent way


The Process Quality Manager lets you monitor and document process data from multiple plants in real time, making your production more transparent. Timely provision of the data improves the profitability of your production facilities.

Using a cockpit, the Process Quality Manager visualizes the various performance indicators and tolerances so that you can identify and resolve problems more quickly. A series of analysis functions help you immediately identify systematic errors, detect trends early, and contain causes so that measures can be taken before a defective product is even made. Numerous reporting functions allow continuous monitoring of the success of the measures.

With the Process Quality Manager, you can achieve a constant increase in productivity, reduce your rework costs, and have a chance to speed up production ramp-ups.


The Process Quality Manager masters the constant challenges of safety-critical tightening processes: a case study

Boosting productivity


Companies in the manufacturing sector are always being challenged to increase their productivity, reduce rework costs, and ramp up production more quickly – all under intense cost pressure. Faults in production are expensive, and can even cost you your competitiveness. You can master these challenges by continuously optimizing your process quality.

Continuous process transparency

Process Quality Manager and Nexo

Processes have to be transparent for continuous improvement to be successful and in order to optimize the application of expert know-how. Tightening experts in the production environment are sought-after specialists, particularly for safety-critical tightening. Only a handful of tightening specialists have the expertise for such critical processes as well as detailed knowledge of the kinds of complications that can occur; in other words, what causes tightening problems and how they can be solved. The tightening expert is therefore a rare “commodity” in the world of manufacturing and needs to be deployed at precisely the right point.


Handling large quantities of process data

Early detection of faults


Every single completed tightening generates a multitude of data, such as torque, rotation angle, and time, for the system to record and store. This quickly creates huge amounts of data that have to be prepared and processed. Companies therefore need to take an intelligent approach to handling these huge data quantities.

Even a slight deviation from the target process can lead to serious failure costs. For this reason, you should identify errors and failures as they occur and proactively inform the tightening experts. Early detection allows you to take preventive action.


Highlights of the tightening data cockpit

Faster process overview of all tightening processes


Tree structure

With its various levels, the tree structure enables a quick and straightforward navigation through plants, areas, lines, stations, tightening applications, and down to individual channels. Configurable color changes (red, yellow, green) at each level depend on the NOK status rates, and therefore inform the user about eventual process disruptions.

At the channel level, a tightening system’s master data as well as the previous 100 tightenings are displayed as bars in a row. A green bar means OK, a red bar means NOK. In analysis mode, the user can click on the bar to open a details window that provides comparison and statistical analyses.

Creating favorites (observing units)

To maintain an overview of many machines, every level can be selected as a favorite in order to gain faster access. This function lets you avoid extensive filtering processes.

tightening cockpit

Managing users/roles/rights

The Process Quality Manager enables the independent management of users, roles, and rights – including authentication. Different roles can be defined for users in dispersed and heterogeneous teams according to their responsibilities, along with the corresponding views and access rights.


Analyzing tightening processes

A variety of views are available to the expert for exact analysis of the tightening process, so that they can quickly identify process changes early on.

In addition to the tightening curve, many other types of assessment are available to enable a systematic analysis of the completed tightenings and to reveal trends early. The other assessment types include a field of nine, single value card, probability plot, histogram, and box plot.


Real-time data acquisition

Documentation - storage of component IDs


Process data is transmitted from the controller of the tool to the tightening software solution in real time, stored in the database, and visualized in the web-based user interface. You can use all common web browsers to access the Process Quality Manager. Users have immediate access to all tightening process data and can intervene if necessary.

With the help of the Process Quality Manager, the component ID for every completed tightening is also stored in the database. This information is of particular relevance when component tightenings need to be precisely analyzed at a later time.


Additional features


  • A range of options allow users to create, save, and send user-defined reports using a wide variety of reporting possibilities.
  • Notification when trends or runs are detected as well as atypical behavior of critical readings.

  • When defined thresholds of NOK rates are reached or exceeded, users are notified in the form of a color change of the plant overview and in the most recent 100 tightening events displayed.
  • Night view (darker layout, which makes it easier for the eyes to adjust during night shifts)


Example of a tried-and-tested configuration


  • 500 Bosch Rexroth tightening systems (firmware 2.4) with a cycle time of 10 seconds
  • Two Linux servers
  • Relational database
  • Web-enabled devices

We are happy to work with you to determine the viability of connecting tightening systems from other suppliers plus other technologies.



Process Quality Manager benefits at a glance


Faster reaction to process errors

Early detection of process risks

Continuous process transparency


reduces failure and reworking costs, results in more output.

enables preventive measures and thus avoids failure costs.

supports continuous improvement and enhances utilization of specialist knowledge.


Realizing savings by using the Process Quality Manager


Using the Process Quality Manager helps specialists identify deviations more quickly and start the analysis without delay.

You don’t have to worry about reporting the error or gathering the required data – the software does that for you.

This means: a considerable reduction in response times throughout the entire process, from identifying a deviation to resolving it. Ideally, these faster response times should enable you to avoid errors altogether.




New business models for machinery and component manufacturers:

For machinery and component manufacturers, the Process Quality Manager offers the potential to enter new business areas in order to benefit from the growth engine of a digitized and connected production. By connecting your devices and components with this software, you as the manufacturer can offer your customers an all-inclusive, worry-free package. You thus provide them with a service for continuous process improvement along with your product. Machinery and component manufacturers themselves benefit as well, since their competitive edge increases, their portfolio expands, and their devices are enabled for Industry 4.0.