The 6 golden rules for handling process data in production

Errors in production can cost you a fortune in the manufacturing industry. We will introduce golden rules for a secure and nearly error-free production.

 

In addition to quality assurance measures prescribed by law, you’ll find further provisions that protect you not only from damage resulting from product liability issues and damage to the company image.

 

Our subjects on the correct handling of process data

1. Electronic data collection instead of paper chaos

The risk of errors if high if data arising during manufacturing processes has to be recorded and evaluated manually, e.g. documents may be filed in the wrong file or data may be documented incorrectly or insufficiently. An electronic data collection puts an end to the paper chaos and allows for a reliable search for product and component-related information anytime.

2. Optimization of training and guidance of staff

Trainings are expensive and often times don’t have a sustainable enough effect on staff. If an employee works at different manufacturing stations, errors in the work process can occur despite thorough training, e.g. due to insufficient working routine. A guide with images and measures for error prevention, however, supports the worker much more efficiently at various work places in production. Based on software functionalities, product quality can be maintained on a consistent and predictable level.

3. Avoiding incorrect assembly

Components that have been incorrectly assembled or which have missing parts require rework. Sometimes, erroneous products end up on the market despite previous quality controls. Cross-check lists and component scans are an efficient and secure way of detecting and combatting errors and quality defects early on.

4. Preventively avoiding product liability damages

Every manufacturer can proactively counter possible product liability damage as early as in the production process. Warning notifications are initiated as soon as certain threshold values are reached. Specific checks at quality gates can also be introduced. This avoids erroneous products from ending up on the market in the first place.

5. Keeping independence from tool manufacturers

In many plants, different stations, tools and software are used. Some of this equipment, however, is tied to a certain supplier, making consistent and independent quality controls difficult or impossible. Supplier-neutral solutions for an integrated, company-wide process data management counter such dependencies. On the basis of standard interfaces, companies can use the latest in tool and station technologies for the long term.

6. Archiving process data

A major requirement by law for the manufacturing industry is to document the manufacturing process in detail and to properly store the data over a long time period. In the automobile industry, this specially affects component joints such as screw fastenings which, in case of failure, may endanger life and limb. The electronically collected process data thereby is archived in an unalterable manner and can be produced in several years’ time if needed as proof.

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