HNS Technical Development Co. Ltd.
Gesztenyefa 4., Győr, 9027 Hungary
Phone: (96) 506-930
Fax: (96) 506-931
e-mail spc@hns.eu

HNS AKS - Failure Monitoring System

Overview

The basic task of assembly line workers is doing the production or the assembling and checking the quality of the parts.

During the assembly process, so during the production process the operators find different failures more or less influencing product quality or mainly causing direct waste.

These failures can be:

• failures of the parts arriving into the station and
• failures during machining or assembly process at the station.

The failure-finding capability of the worker also significantly influences the quality of delivered product.

The reasons influencing this capability can be:

• intentional mistakes (fraud, adulteration of facts for example because of convenience reasons),
• indirect mistakes (mistakes from distortion, rounding) and
• unintentional mistakes (limited to - 80-90% - fault-finding capability, mistakes caused by awkwardness or tiredness).

The producing process (continuous) control of blank and product makes possible the previous production phase detection of possible failures and the earliest separation of the faulty parts from production. The control is necessary by all production processes where the fully consistent product quality and the quality suitability can not be guaranteed, and where the possible losses due to the mistakes are multiple higher than the control costs.

Because of the unintentional mistakes such a system is necessary to be installed which is able to

• record the data of errors found by workers on the product (Do not forward faulty product!) and based on these data is able to
• drive control cards for failure rate changes and is able to automatically identify the deregulations and call the responsible staff in case of deregulations (Out of Control has been occurred).

We developed the HNS AKS Failure Monitoring System based on these requirements. A directly in production useable failure data-collecting and online failure monitoring system can be formed with the integration of the HNS AKS and the HNS SPC systems.

The data collecting system has to be installed and used carefully; the human and the respect of employees have to come in view during the implementation! The commitment of employees is very important because significant quality improvement of the delivered product can be reached just in cooperation with employees.

The HNS AKS Failure Monitoring System stands by the next three parts.

SPC terminals

The SPC terminals installed at different workstations and networked make data input and displaying tasks.
The employees working on the workstations can record the data codes identifying the found failure on these terminals (the failures can be failures found on incoming parts, failures existing and do not find so forwarded at a previous workstation, furthermore own failures). The SPC terminals accept the piece counting sign of the given workstation (automatic piece counting) and as the given workstation has failure detection capability then these SPC terminals accept the digital signals concerning to the automatically detected failures.

HNS AKS program

The HNS AKS program expediently running on the workline PC performs the server tasks necessary in the system. It means handling of SPC terminals, support of two-way connection with the HNS SPC system, handling of production administration (start and stop the production, production line configurations and production data), logging as well as visualizing of on-line failure data of the production.

HNS SPC

The basic data are there in the HNS SPC system, for example product ID's, definitions of variables and attributes, workstation data and process settings necessary to the operation of HNS AKS system; the HNS AKS system is able to directly reach HNS SPC system data. It is possible to forward data existing in HNS AKS system towards the SPC system and evaluate these data by SPC tools.

Main features of the HNS AKS system

• Handling of workstation configurations.
• Handling of the working numbers.
• Handling of product/machine/tool configurations at production start (it happens according to the production system data arranged in the HNS SPC system, so the administration activity about production system is unnecessary).
• Production start, re-starting of interrupted production.
• Identification of the workers.
• Counting of the number of completed parts, number of wastes and failures for the workstations.
• Counting of the total number of completed parts, summarized number of wastes and failures.
• Counting of the forwarded, own and forwarded own failures.
• Counting of the failures of foreign parts.
• Possibility of errors weighting.
• Loading of tool and mould ID's from external databases.
• Connecting of part and good/bad part counting signals of production/assembly equipments with in-built controller (PLC).
• Visualization of data related to the production (work number, product code, worker ID, etc.) at each workstation.
• Visualization of part number and number of failures at the workstations.
• The failure data can be forwarded from the HNS AKS system to the HNS SPC system on-line.
• The system is actually able to serving up to 15 workstations.
• Central visualization screen for displaying the production and failure data.
• Visualization of detailed data of the workstations on the central visualization screen.

According to our experiences, the commitment related to the quality and quality assurance of the group and each worker within the group can be largely increased by the usage of the program – the efficiency of worker self-control can be improved, it means reduction in quality costs, which became measureable at the same time as the system was implemented. The system includes as further possibility that it allows decoupling of line worker self-control from EOL testing.

The data forwarded towards HNS SPC system and stored in HNS SPC database, furthermore processed in HNS SPC program allow the process control and the widely usage of the HNS SPC functions, so among others the efficient support of quality development.

Scope of delivery

The scope of delivery includes the SPC terminals and the HNS AKS program (PC software) (up to 15 SPC terminals can be installed within a production system).

In case of customer needs we undertake the system installation and configuration (UTP cabling, installation of SPC terminals, installation and configuration of HNS AKS program, re-examination of environment necessary in HNS SPC system as well as its arrangement if it is necessary), furthermore training about the usage of the system.

 

HNS Technical Development Co. Ltd. • Gesztenyefa 4, Győr, 9027-Hungary | HNS ® • Copyright © 2009-2012 | HNS SPC • Copyright © 1989-2012 | All rights reserved.