Skip to content

Custom Solutions

Solutions For Every Industry

When a manufacturing process requires measurement of pressure, distance, or time, in-process monitoring and inspection technologies can be integrated to ensure quality. Our passion and ability to problem solve and provide unique solutions for process monitoring applications has been the foundation for our success.

  • Mechanic fixing part at on the bottom of a car.
  • A man and women looking at computer screen on a factory floor.
  • Man measuring colourful wires with other staff in the background.
  • Young women working in factory working with wires.
  • Close up of hands holding yellow wires with a computer screen in the background.

Monitoring Ensures Quality

Process monitoring is a proven solution for repetitive manufacturing processes which exert force during the material forming process. The measured resistance during material forming and compression results in a characteristic force signature and monitoring this signature of every machine cycle for repeatability is an effective method for assurance of quality.

Benefits include:

  • In-process monitoring on 100% of parts
  • Capture defects at the source prior to parts moving to next stages
  • Manage maintenance to reduce costs and increase operational efficiency
  • Catch hidden defects undetectable by visual or dimensional inspection
  • Puts the focus on the process – sustainable gains in efficiency, scrap reduction, and quality

We tackle large and small projects and are virtually unlimited in our ability to adapt our quality assurance devices, sensors, wire inspection and software solutions for in-process monitoring applications. Take a look at some of our popular custom solution applications for in-process monitoring and ask us how we can customize a solution for you.

Baffle Stuffing

Monitoring the characteristic force profile during the precise press-fit of the baffle assembly into the muffler housing and comparing this to a signature profile provides assurance that every part was assembled within tolerance limits.


Modern clinching and toxing methods have opened up new possibilities for the processing of high-quality fine sheet metals. This technique for metal joining can be effectively monitored for quality. Process variation monitors work well with both manual and automatic material feed systems.

Cold Heading

Cold heading and high speed forming of fastener components can be effectively monitored during stamping processes. Each machine cycle is monitored for process variation relative to control limits.

End Forming

The correct tube end form ensures a proper seal of the pressurized brake and fuel lines for automotive applications, making it a mission critical to the safe and reliable operation of a vehicle. Monitoring the force during the end forming process and logging this data ensures product quality and traceability.

Mandrel Bending

Process variation monitoring for mandrel bending involves sensing the pull or tension force on the mandrel rod during every bend cycle. If the pull force exceeds or drops below normal control limits then the process is degrading and the OES product can alert the operator.


Non-intrusive piezo strain sensors can be attached to the rivet head or rivet clinching head to provide a signal output relative to the strain energy during the riveting process. Each energy profile is captured and analyzed for variation within predefined control limits.


Stamping processes typically cycle at high production rates and can degrade quickly leading to quality issues, unnecessary scrap, and potential tool damage. Process variation monitoring is an effective method to detect degrading conditions before they exceed established limits.


Monitoring the welding process for each production cycle will ensure that the correct material is in place and is orientated correctly prior to the weld cycle. Utilizing a linear position sensor, OES has effectively deployed process variation monitors for use in seam welding assembly of automotive panels, nut welding fasteners onto metal sheets, and ultrasonic welding of components.

Achieve Quality Assurance Excellence

Since 1980, we’ve provided global partners, manufactures and machine suppliers quality assurance devices that exceed their expectations and quality of parts being produced.

How can we help you?