Fault-free production according to the “Poka-Yoke” principle is the focus for the software manufacturer CSP.
Errors in production can be extremely costly for the manufacturing industry. CSP GmbH & Co. KG has now prepared a list of the golden rules that must be followed in production monitoring and thus reliable and largely fault-free manufacturing. Measures on quality assurance in production, stipulated by the lawmakers, are complemented by additional precautions that can help companies avoid product liability issues and image damage, amongst others. Process data acquisition as well as its analysis and archiving also play a major role at this. In the coming weeks CSP will provided additional information on the six golden rules to interested companies. You can subscribe to them at the CSP homepage via email!
- Electronic data acquisition instead of paper chaos
The risk of error is high when process data generated in production processes still require manual recording and reporting. For example, documents could be filed in the wrong folder or data may be documented faulty or incomplete. Electronic data acquisition puts an end to the paper chaos and allows tracing respective components and batches. Product and component-specific information can be searched reliably at any time in the archive.
- Optimised worker orientation and instruction
Training programs are expensive and often lack sustainability. If a worker is employed at different production stations flaws in the work process may still occur in spite of training undergone because, e.g. of a lack of work routine. By contrast, image-guided instruction as well as preventive measures for error prevention support workers much more efficiently at changing work stations in production. Based on software functionalities, quality assurance in production can be maintained on a uniform and predictable level.
- Avoiding faulty assemblies
Incorrectly assembled components or parts where components are missing require respective rework. Faulty products sometimes enter the market in spite of quality control. The use of checklists and component scans is more efficient and reliable. Error and quality deficiencies can be detected early on based on such production monitoring, and corrective measures can be easily employed.
- Prevention of product liability damages
Any manufacturer can actively counter potential product liability damages already during the production process. For example, warning messages can be triggered immediately when reaching certain thresholds and targeted controls can be performed at quality gates. Such quality assurance in production and tracing thus enabled prevent faulty products from even being sold.
- Maintaining manufacturer independence
Many factories often use a variety of diverse machinery, tools and software programs. Sometimes interdependencies with specific manufacturers come into play, though, and this makes consistent and independent quality control difficult or even impossible. Manufacturer-independent solutions for process data acquisition as well as integrated company-wide process data management protect against such interdependencies. Based on standard interfaces companies can utilise the latest tool and plant technologies flexibly and for the long haul.
- Process data archiving
Detailed documentation of the manufacturing process and proper data storage over a longer period of time is an essential requirement of the lawgiver to the manufacturing industry. This affects, for example, component connections in the automotive industry, especially screw joints, that are critical for the safety of people’s lives. Electronically acquired process data is archived here unalterable and can be presented any time as proof even many years later.
“Ensuring maximum quality”
Strategic quality assurance has a very high priority in production: “In case of a complaint we would be able to prove in detail how exactly and error-free assembly was carried out. The advantage is the fact that our training effort for orientation to new products is much lower”, confirms Johannes Zizler at Knorr-Bremse Systems for railbound vehicle, responsible for work planning of the brake control competency center. “Ensuring top quality is extremely important for Knorr-Bremse. Damages that may develop as a result of a faulty brake system quickly amount to millions. Investment into quality assurance thus pays off very quickly”.
Author: Leonie Walter, Walter Visuelle PR GmbH