11 July | 2 MIN READ
How to Achieve High Product Quality in Custom and High-Mix Production
High-mix manufacturing makes it possible to deliver highly customized products with the efficiency and cost benefits of mass production. But as customer expectations rise, so does the challenge: how can manufacturers maintain high product quality while meeting the demands of built-to-order production? Striking the right balance between flexibility and consistency has never been more critical.
Why Quality Suffers in Custom, High-Mix Manufacturing – and How to Fix It
High-mix manufacturing allows companies to deliver individually customized products at scale, offering a key competitive advantage. But this flexibility comes with a new set of challenges – particularly around quality control in custom production.
Today’s customers expect not only personalization but also rapid turnaround and trend responsiveness. As mass customization becomes mainstream, products increasingly reflect short-lived fashions or specific user preferences. This forces manufacturers to constantly update their offerings and adapt production lines quickly.
Even in traditional mass production, managing quality across multiple product variants is complex. In high-mix environments – where hundreds of built-to-order configurations may exist – the challenge intensifies. Existing quality assurance processes, which often rely on consistency and repeatability, often struggle to keep up.
Yet one factor remains non-negotiable: product quality. Regardless of how customized a product is, customers expect flawless execution. That means quality control systems must evolve to match the flexibility and speed of high-mix production. As noted in a McKinsey article on transforming quality management, adopting digital tools, data-driven decision-making, and agile QA practices is essential to stay competitive.
Dynamic Quality Control in High-Mix Production
In high-mix environments, no two products are exactly alike – which means quality control can’t follow a one-size-fits-all approach. The ATS Inspect solution enables a fully adaptable visual inspection process, designed to match the exact configuration of each built-to-order unit.
When operators begin an inspection, they’re presented with CAD models or product images that reflect the specific unit being checked. These are automatically pulled from the PLM (Product Lifecycle Management) system , ensuring accuracy. Any defects can be marked directly on the model, streamlining the process and reducing ambiguity.
Electronic checklists also adjust dynamically. Inspectors see only the questions relevant to that specific configuration, with correct responses updated in real time. This personalized process ensures every customization is properly verified, without adding complexity or manual effort.
Connected directly to the shop floor, ATS Inspect software can automatically flag issues, hold defective units, or route them to rework, ensuring that no product leaves the plant with a quality defect or build error, no matter how unique it is.
Simplify Quality Audits with ATS Inspect Traceability
In high-mix manufacturing, staying audit-ready is essential, but paper records and spreadsheets can’t keep up with the speed and complexity of custom production. Whether it’s a formal audit, a request from management, or a quality report on a specific component, having reliable, searchable data is critical.
With ATS Inspect, traceability is built in. Every inspection is digitally recorded, including unit-specific details such as configuration, defect locations, and operator inputs. This ensures a complete, timestamped audit trail for every product – no manual tracking required.
Thanks to real-time reporting capabilities, you can monitor quality levels globally, review specific units or variations, and generate reports in just a few clicks. If a problem arises, you can drill down into your data to identify root causes (whether tied to a component, process, or operator).
By replacing paper-based systems with ATS Inspect’s digital inspection software, manufacturers gain confidence, speed, and accuracy in both routine reviews and surprise audits.
Delivering Customization Without Compromising Quality
Today’s customers expect personalized products that reflect their tastes. Mass customization has made this possible, allowing consumers to select features, finishes, and configurations that give them a sense of ownership and uniqueness.
But while variety is welcome, quality is non-negotiable. Customers may accept bold designs or unique configurations, but they will not tolerate defects or inconsistencies.
With ATS Inspect, manufacturers can scale product personalization while maintaining consistent, high-quality standards. Every custom build is inspected and verified – ensuring that personalization never comes at the expense of product quality.
