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VIDEO: PINpoint MES System Production Analytics Demonstration – Part 3 (Valuable Reports)

PINpoint ultimately provides our clients valuable manufacturing reports integral to improving manufacturing processes. PINpoint ‘Production Analytics‘ comes pre-loaded with many manufacturing reports you can customize yourself, and save as favorites for daily viewing, including indispensable Cycle Time reports, Andon and OPE reports (see example Figure 1).

 

manufacturing reports


Manufacturing Reports Video

PINpoint manufacturing intelligence reports demonstrated in Part 3 of the Production Analytics Demonstration video below:

+ Daily Average Cycle Time by Station Report
+ Product Average Cycle Time by Station Report
+ Daily Average Cycle Time by Station Operator Report
+ Daily Bypasses by Station Report
+ Daily Bypasses by Reason Report
+ Total Daily Exceptions Report
+ Daily Exceptions by Station Report
+ Product Exceptions Report
+ Fastening Rundown Report
+ Fastening Tool ID/Serial Number Report
+ Daily Job Starts Report
+ And Many More Manufacturing Reports

 


Manufacturing optimization is only possible with the analysis of the data or manufacturing reports afforded by the manufacturing execution system. PINpoint is the only out of the box MES system that both ‘monitors’ and ‘controls’ the assembly line, all data which is captured in the PINpoint “Cube” multidimensional database for manipulation by the software’s Production Analytics feature.

Every tool a manufacturer needs to improve assembly line processes is included in the package; with PINpoint there is no extensive consultation required, there is no custom PLC programming, there are no modules to add, and therefore no added labor cost. By simply opening a web browser on any computer, tablet or phone to access the PINpoint portal website, the user can configure any aspect of assembly in real time. For leading manufactures Worldwide PINpoint is the go-to error-proofing system; it is a proven, turn-key, value-added, long-term manufacturing operations management (MOM) solution.

Headquartered in Burlington, Ontario, PINpoint services industry internationally from their offices in Canada, the United States, and China. For more information please call: +1 (905) 639-8787, email: sales@pinpointinfo.com or visit: http://pinpointinfo.com/

RELATED LINKS

See the “Why PINpoint?” prezi presentation here:
https://prezi.com/adp9dhp3vgn0/why-pinpoint-manufacturing-execution-system-mes-manufacturing-operations-management-mom-solutions/

 

Evolution of the Andon System

PINpoint continues to evolve its time proven manufacturing software with the addition of Andon system functionality into SmartScreen, the station level software that station operators interact with daily. SmartScreen touch displays are vital to the error-proofing solution; each and every configured user, be it line worker, area supervisor or plant manager is guided by them. When an operator first logs in at their station SmartScreen identifies who the person is, and verifies whether they are qualified to do the work assigned. If the worker is not certified or trained to perform the process steps SmartScreen will not allow the worker to proceed, and tools or any connected devices will remain off or locked.

Once a station operator is verified they are presented with all the information they need to complete their tasks, starting with paperless work instructions and quality alerts; SmartScreen is the workers personal guide to complete the process steps in the cycle or TAKT time allotted. As work proceeds and issues arise, the Andon system functions are prominently displayed on the SmartScreen (see Figure 1.). As shown the SmartScreen is quite informational and interactive, it is designed to lead its user in the most efficient manner to complete process steps and resolve issues quickly on-the-fly. As problems happen the line operator has multiple Andon system functions to choose from; a ‘red’ attention button can be pressed for critical problems requiring a line interruption; or a ‘yellow’ button to call for supervisor help, and when materials are low a ‘blue’ button is easy to spot and press.andon system

Figure 1. PINpoint SmartScreen Andon System


You can also add custom buttons; PINpoint is a ‘configurable’ web based manufacturing execution system, therefore the Andon system and all components of SmartScreen can be customized for your unique manufacturing environment. Once pressed a number of notifications can be triggered, including the turning on of stack lights, and/or alerts can be displayed on big screens for all to see (with colors, graphics or video to draw attention); also audible notifications, email and text messages can be sent. Further, the PINpoint Andon system is much more than push buttons and stack lights, it can be configured to raise notifications on its own, in addition to the manual inputs by the station operator.

Should a line worker for example fall behind in completing their process steps, the system can be configured to raise a Cycle Time ‘Warning’ Event. Essentially as cycle time is depleted and the SmartScreen tracks the line operators progress, a time threshold can be configured to raise a notification alarm before the issue escalates further; a warning to inform both the operator of their situation and to draw attention to the area line supervisor for help. A Cycle Time ‘Over’ Event is also configurable, should the line operator not complete the process steps in the configured cycle time a notification can be raised.

The configurablility of the Andon system or manufacturing execution system is as easy as opening a web browser to access the PINpoint portal; from there the process engineer can configure the assembly line and process steps timing using ‘SmartBuild‘, schedule production with ‘Scheduler‘, verify product status and location with ‘Tracking‘, and access manufacturing intelligence with ‘Production Analytics’. With Production Analytics you output reports crucial to improving assembly processes, including Andon Analytics (see Figure 2.):

 

Andon System

Figure 2. Andon System Analytics

 

Changes and tracking are in real time, and all of these features and more are provided in one package, making PINpoint the most value-added Andon system and manufacturing execution system on the market – everything a manufacturer needs to optimize their operations is available out-of-the-box, PINpoint is a long-term proven solution that is designed to be flexible and scalable to grow with you as your manufacturing operations expand into the future.

Please do not hesitate to contact PINpoint with any questions, please call: (905) 639-8787, or email: sales@pinpointinfo.com or visit: http://pinpointinfo.com/

ANDON SYSTEM RELATED LINKS

Interactive Presentation: https://prezi.com/adp9dhp3vgn0/why-pinpoint-manufacturing-execution-system-mes-manufacturing-operations-management-mom-solutions/

Production Analytics Demo: https://www.youtube.com/watch?v=uLAGW_6faiM&list=PLvRjiER8QiZo3CyNn-i9Pc7oAxT7M65Ig

VIDEO: PINpoint MES Production Analytics Demonstration – Part 2 (Microsoft Excel)

PINpoint MES Production Analytics

In Part 2 of the PINpoint MES System ‘Production Analytics‘ demonstration series, software Engineer Marc Seguin shows how both ‘Production Analytics’ software and Microsoft Excel can be used to access and manipulate the exact same data from the “Cube” multidimensional database.

Marc demonstrates the use of pivot tables to work the manufacturing data in Excel. He shows how the data can be transformed into powerful reports; charts and graphs which are absolutely essential for your continuous improvement initiatives.


PINpoint continues to evolve its time and industry proven manufacturing software technology; since 1997 the PINpoint MES or Manufacturing Execution System ‘Solution’ has been pushed-forward and innovated alongside some of the most recognizable manufactures in the World (Caterpillar, Ford, Chrysler, Hyundai, Boeing, Polaris, and many more).

Please do not hesitate to contact PINpoint with any questions, please call: (905) 639-8787, or email: sales@pinpointinfo.com or visit: http://pinpointinfo.com/

PINPOINT MES RELATED LINKS

Interactive Presentation: https://prezi.com/adp9dhp3vgn0/why-pinpoint-manufacturing-execution-system-mes-manufacturing-operations-management-mom-solutions/

Production Analytics Demo (Video): https://www.youtube.com/watch?v=inDK_yAuGgs

WHITE PAPER: Maximize Fastening Tool Effectiveness and Save Money with Manufacturing Execution System Control.

Introduction

Given the vast array of manufacturing fastening tools and assembly line device products available on the market, it can become overwhelming to identify which products you should purchase; as recommended by consultants or the tool suppliers themselves. Is it worth spending ‘extra money’ because of claims of added features and benefits? The question is, what is it you really-need to accomplish the task? What if you could purchase the most basic or cost-effective tool ‘needed’ for the job, with saved money in hand to put towards the over-all manufacturing execution system (MES) solution you really need? This is proven to be so, and fastening tool processes are a prime target application for manufacturers to improve their existing manufacturing operations (upgrade), or for new project specification; please consider the following.

Fastening operations play an integral role in the manufacturing of quality parts for cars, transport trucks, heavy machines, agricultural equipment, airliners and more. The fastening of critical bolted joints especially, involves controlling both the input torque and angle of turn in order to achieve the desired proper preload result of the bolted assembly. These safety critical parts are designed to not fail, and therefore must be verified to be without defect (without fail) prior to shipment to the original equipment manufacturer (OEM). To aid in this goal, fastening tool manufacturers incorporated ‘error-proofing’ measures into their device solutions; although they cannot solve the problem entirely. Therefore, regardless of the class of fastening tool or expense, the tool itself will not be monitoring and controlling all aspects of the assembly process, including the human. So why spend extra money unnecessarily, only to operate at a deficit from day one?

Manufacturing Execution System Case Study

A multi-national heavy equipment manufacturer lived the exact case study being described here, and in the end achieved an outstanding result of a ninety-four percent (94%) decrease in bolted joint failures, and with Warranty claims reduced the same in turn (see figure 1). Previous to the integration of the manufacturing execution system the customer made a very substantial investment into the latest fastening tools available at the time, with error-proofing features built in to verify bolt input torque and turn angle. The customer monitored the use of the tools over a twelve (12) months period only to be disappointed by a very poor result, i.e. there had been no change or improvement in the number of bolted joint failures and Warranty claims resulting from the upgrade of the fastening tools after the 12 month’s pilot.

manufacturing execution

Figure. 1: Bolted Joint Failures and Warranty Result after MES/MOM implemented. 

 
The customer had failed to solve the root problem, which no assembly tool or device can do; there are so many factors at play between human and machine at any given moment, and that interaction must be “monitored” and “controlled” by the central decision making machine that is the manufacturing execution system. Imagine the MES system as the CPU of your manufacturing operations; a software you work and live with on a daily basis, which is easily navigable and accessible on any computer to check the status of manufacturing operations at anytime and make changes if necessary. The MES system allows you to keep on top of your process steps as they happen, because any error in assembly that is ignored or left unchecked is a potential unknown defect which can pass process after process and ultimately into the field and the end product. The MES system creates a fail safe means of ensuring defects do not go undetected; and further, in the process important data is captured which can be analyzed later to further enhance operations.

To keep costs down and ensure jobs are done to specification with only quality parts being produced, customers simply need to purchase the most cost-effective electric fastening tools, and specifically those with a built in transducer. Further, the most basic MES system as offered by PINpoint is not a large investment; in fact, their product is the ideal “entry-level” manufacturing execution system, which doubles as an innovative software based Andon solution with powerful production analytics capabilities built-in to help you define cycle time. With the use of MES software you can control any make and model of fastening tool through the use of open protocol. What does this mean for you the manufacturer? Unprecedented error proofing. 

The ISA-95 model of activities in manufacturing operations systems divides the ‘activities’ of manufacturing into 5 different levels (see figure 2.): with Level 0 being the production process, or the manufacturing line; Level 1 the tools, sensors, devices; Level 2 automated process control, PLCs; Level 3 manufacturing operations management (MOM), the manufacturing execution system (MES); and Level 4 being business planning and logistics, the enterprise resource planning level (ERP). PINpoint creates the perfect marriage and communication, or ‘conversation’ between all levels of ISA-95 – the MES is the central processing center of manufacturing operations with the ability to both “monitor” and “control” or direct the actions of humans and machines, and in turn report the results in meaningful documents which are invaluable in your quest to improve/optimize manufacturing operations further.

manufacturing execution

Figure 2: MES/MOM is central to the success of manufacturing operations management.

MES/MOM Software

The MES or MOM system is central to deciphering and creating actions from all the manufacturing data being received (monitored), in order to act (control and alert) in real time accordingly, and in order to output the granularity of manufacturing, or Andon data, essential to maximizing quality and production output (OEE) and optimizing process step cycle time. Therefore as proven and recommended, consider the MES system to be the primary focus in your plans to improve manufacturing processes, and as the starting point for your new project; because the tools and devices you connect to the network are secondary in the over-all manufacturing optimization scope of things; the fastening tools will serve their basic purpose to accept inputs and transmit outputs to the MES, the vital data needed for the manufacturing execution system to verify and command processes. The elimination of the need to spend additional money for unrequired features on fastening tools is notable, since so long as the fastening tool has a built in transducer it can be paired quite effectively via open protocol to communicate with the MES to ensure error-proofing in fastening operations is never compromised.

The manufacturing execution system software has been developed since 1997 and it continues to be evolved and pushed-forward by leading manufactures. Thoroughly proven it is in use daily Worldwide in multiple languages by leading automotive, aerospace, heavy machinery, agricultural, and power sports vehicle manufacturers. The software is meticulously designed and tested to ‘Information Technology Infrastructure Library’ (ITIL) standards before any official version release.

Headquartered in Burlington, Ontario, PINpoint services industry internationally from their offices in Canada, the United States, and China. For more information, please contact 905-639-8787sales@pinpointinfo.com or visit our website http://pinpointinfo.com/

RELATED LINKS

Interactive Presentation: https://prezi.com/adp9dhp3vgn0/why-pinpoint-manufacturing-execution-system-mes-manufacturing-operations-management-mom-solutions/

Production Analytics Demo (Video): https://www.youtube.com/watch?v=inDK_yAuGgs

VIDEO: PINpoint MES Systems Production Analytics Demonstration – Part 1 (Introduction)

PINpoint continues to evolve its time and industry proven manufacturing software technology; since 1997 the PINpoint Manufacturing Execution System (MES) ‘Solution’ has been pushed-forward and innovated alongside some of the most recognizable manufactures in the World (Caterpillar, Ford, Chrysler, Hyundai, Boeing, Polaris, and many more). 

In this video series we dig deeper into the PINpoint manufacturing intelligence; ‘Production Analytics‘ is a most powerful tool which allows manufacturers to drill-down into all captured assembly data (as “monitored” and “controlled” by the manufacturing execution system) and transforms it into meaningful manufacturing optimization reports.
  


   

In Part 1 of the series PINpoint Software Engineer Marc Seguin focuses on ‘Production Analytics‘ software specifically; he guides us through the various features including how to set search criteria, manipulate data, save favorites, and output reports.

Either PINpoint or Microsoft Excel can be used to access and manipulate the data; i.e. to perform “Cube” or multidimensional database searches to hone in/drill down on the data that is the most relevant for analysis.

Please do not hesitate to contact PINpoint with any questions, please call: (905) 639-8787, or email: sales@pinpointinfo.com or visit: http://pinpointinfo.com/

MANUFACTURING INTELLIGENCE RELATED LINKS

Interactive Presentation: https://prezi.com/adp9dhp3vgn0/why-pinpoint-manufacturing-execution-system-mes-manufacturing-operations-management-mom-solutions/

Production Analytics Demo (Video): https://www.youtube.com/watch?v=inDK_yAuGgs

WHITE PAPER: New Supercar Engine Assembly Perfected by Manufacturing Execution System

Introduction / Summary

This document summarizes the manufacturing execution system (MES), or manufacturing operations management (MOM) solution implemented by a leading Automotive manufacturer to manage the complex assembly of the engine for their new Supercar. The MES/MOM was integral to ensure each and every single of the nearly two-thousand (2,000) process steps involved to build the engine were completed to the set specifications or tolerances without fail.

MES/MOM ensured zero-defects during the assembly of the engines since it monitored and controlled all operations; all tools and devices, and the line workers themselves since the MES/MOM directed them from job start to end. The MES/MOM verified worker credentials, provided work instructions, and confirmed that the materials and tools were properly selected for the exact task at hand.

Destined for the Automotive manufacturer’s highest-performance GT sports car (see Figure 1), the twin-turbo charged V6 “EcoBoost” engine is vital to the success of the final product. Given the intricacy of the engine and the number of steps needed to assemble it, and its high tolerances, the MES/MOM proved indispensable.

Assembly Background / Problems

Considering the Supercar is not mass-produced, or is production limited, i.e. these cars are produced in low volumes and are of very high complexity; this low-volume or high-complexity production established the need for an extremely flexible manufacturing system to maximize quality and time-to-market speed while keeping costs down. A flexible MES/MOM solution was an absolute necessity due to the bespoke nature of every engine.

 

assembly-pinpoint-manufacturing-execution-system

Figure 1: Ford GT Supercar.

 

Of particular significance was the error-proofing of the crankshaft and the main housing bore, two (2) parts which are manufactured to extremely tight tolerances in order to fit together precisely. The method or sequence of the assembly of these matching parts to the engine creates an inimitable scenario whereas both parts become separated early on in production. It was critical that these unique parts always married together at the respective assembly station without fail.

The other complexity was that the engine was comprised of various parts with varying bolt sizes, and therefore different tools would be needed, as well as different sized sockets. Error-proofing was essential to ensure the correct fastening tool and socket were always selected for the task at hand. 

Solution

By implementing a MES/MOM to manage every manufacturing operation the customer was enabled to achieve the highest level of error-proofing to produce a quality product while keeping costs down. The engine assembly starts with the creation of an ‘Engine Birth History Report’ which is unique to each and every engine or serial number. The engine birth history report follows every engine (Figure 2) throughout the life of its assembly, and identifies all of the captured process steps or assembly data into a central database (SQL server).

Every single detail is important, right down to verifying the worker and their timing, what tools they select, which socket, and what part. In the case of the crank shaft each part is identified by matrix barcode which must be scanned into the MES/MOM; once the first part’s unique specification is input, the second matching part must be matched by another worker at a different station later on. If the parts do not match an alert is raised actioning the next steps to remedy the situation.

assembly-pinpoint-information-system

Figure 2: ‘EcoBoost’ engine.

The MES/MOM’s feature of “cross station investigation” highlights the ‘feature based’ or made-to-order (MTO) capabilities, or flexibility inherent in the manufacturing operations management solution. The engine birth history report in this case mapped out exactly all parts, tools to be used, matching sockets, fastening tolerances, and thousands of process steps unique to the assembly of each and every engine.

By verifying and tracking which crankshaft serial number was selected in the first station, the cross station examination could be performed in the subsequent station, i.e. verifying the specific diameter crankshaft selected in the first workstation, which directly correlated to the main bore housing diameter in the second station. The MES/MOM performed the cross station examination to ensure the married parts always met, any deviation from this stopped the process, locked the assembly tool, and raised an Andon alert.

 The other crucial error-proofing technique needed involved the tracking of fastening tools and sockets required to complete any given assembly process step. This multiple tool coordination” was accomplished by introducing a MES/MOM ‘Socket Tray’ socket verification system (Figure 3). The Socket Tray features separate ‘trays’ or slots in which the sockets seat and are presence detected via proximity sensors. The MES/MOM instructs and then track and verifies the line worker’s actions as she/he proceed in the fastening operation; firstly, verifying the correct ‘nutrunner’ assembly tool was selected, and then by verifying the correct socket was removed from the tray. The line worker next fastened the appropriate bolt as directed by the MES/MOM until the set fastening tolerances of input torque and angle were met.

 

assembly-pinpoint-information-system

Figure 3: Socket verification system. 

Further to the accomplishment of managing the bespoke manufacturing of each “EcoBoost” engine, MES/MOM provided the manufacturer with indispensable recorded process data which served to further improve all aspects of production including cycle time. As data was gathered and analyzed the manufacturer was able to optimize and improve assembly timing by identifying bottle necks and being able to re-configure processes by re-allocating time or tasks.

MES/MOM Software

The MES/MOM software has been developed since 1997 and it continues to be evolved and pushed-forward by leading manufactures. Thoroughly proven it is in use daily around the world in multiple languages by leading automotive, aerospace, heavy machinery, agricultural, and power sports vehicle manufacturers. The software is meticulously designed and tested to ‘Information Technology Infrastructure Library’ (ITIL) standards before any official version release.

Headquartered in Burlington, Ontario, PINpoint services industry internationally from their offices in Canada, the United States, and China. For more information please contact 905-639-8787, sales@pinpointinfo.com or visit our website http://pinpointinfo.com/solutions

Conclusion

The MES/MOM was integral to monitoring and ensuring control of the nearly two-thousand process steps involved to build the engine. These tasks had to be completed to the set specifications or tolerances without fail, including the challenge of cross station parts coordination. Error-proofing was required at a high-level to ensure zero-defects during the assembly of the engines. By using MES/MOM to monitor and control all process steps, including all tools, devices, and the management of the line workers themselves, the opportunity for a failed or cheated process step to occur was eliminated.

MES/MOM played an integral role in guiding the line worker to successfully accomplish each process step, right down to verifying that they selected the correct tool and socket, and materials; and by confirming the operation happened to within predetermined tolerances in a predetermined time.

Given the intricacy of the engine and the number of steps needed to assemble it, and its high tolerances, the MES/MOM proved indispensable. For low volume or high-complexity production, MES/MOM proves to be the most flexible and thorough manufacturing execution system; it proved to maximize quality and time-to-market speed while keeping costs down.

RELATED LINKS

Interactive Presentation: https://prezi.com/adp9dhp3vgn0/why-pinpoint-manufacturing-execution-system-mes-manufacturing-operations-management-mom-solutions/

Production Analytics Demo (Video): https://www.youtube.com/watch?v=inDK_yAuGgs

VIDEO: Join Pro Angler Byron Velvick on a Factory Tour at Mercury Marine in Fond du Lac Wisconsin

VIDEO

Join Pro Angler Byron Velvick on an all-encompassing tour of the Mercury Marine factory in Fond du Lac, Wisconsin. Mercury Marine achieves manufacturing excellence by ensuring zero defects in their assembly processes with MES/MOM software.
 


PINpoint’s manufacturing execution system (MES) / manufacturing operations management (MOM) software has been developed since 1997 and continues to be evolved and pushed-forward by leading manufactures. Thoroughly proven it is in use daily Worldwide in multiple languages by leading automotive, aerospace, heavy machinery, agricultural, and power sports vehicle manufacturers. The software is meticulously designed and tested to ‘Information Technology Infrastructure Library’ (ITIL) standards before any official version release. Headquartered in Burlington, Ontario, PINpoint services industry internationally from their offices in Canada, the United States, and China.

WHITE PAPER: Aerospace Manufacturer Enabled by Manufacturing Execution System to Produce Safety Critical Electronics

Introduction / Summary

This document summarizes the manufacturing execution system (MES), or manufacturing operations management (MOM) solution implemented by an Aerospace electronics parts manufacturer in order to introduce full-accountability into their assembly processes. The MES/MOM delivered “integrity of process” by providing a control system which managed all aspects of their electronics assembly process; and created a closed-loop of accountability, delivering the desired results every-single-time.

A critical aspect to the achievement of their goal was the management of a new assembly line workforce. The true test of the dependability on the MES/MOM system was it empowered operators with little to no experience to build sophisticated electronic components to the highest quality standards. It is also noteworthy that the MES/MOM was able to be integrated and operational in a very short timeframe in less than four (4) days.

Due to the speed of implementation and the reliability of the MES/MOM system the customer was able to ramp up production quickly while ensuring quality. Ultimately over the long term the Aerospace manufacturer found the MES/MOM so reliable that they were enabled to scale-back on expensive testing that was designed to catch defective products, which in itself represented significant cost savings.

Background / Problems

As a part of the proving process the Aerospace manufacturer had already implemented the MES/MOM on the first electronics assembly line. It was thought the following plant-wide implementation would be months later, although due to end customer delays this turned into nearly a two (2) years wait, which was much more time than needed to prove out the system.

During this time the manufacturer was able to define the best methods or process steps (based on facts and figures) in order to manufacturer the highest quality electronics, i.e. motor controllers destined for ‘Dreamliner’ jet airliners.

Electronics-PINpoint-manufacturing-execution-system

Qatar Airways 787 “Dreamliner” jet.


It had actually only taken the Aerospace manufacturer a few days to figure out and realize the power of the MES/MOM and how it would be invaluable once full production across all four (4) assembly lines started. They were ready to fully-implement the MES/MOM, but the Original Equipment Manufacturer’s (OEM) schedule for delivering the 787 airliner kept getting pushed out.

The OEM delays continued month after month; the Aerospace manufacturer would be instructed to ramp up production and then stop, then again ramp up and stop. This happened over and over and therefore delayed the Aerospace manufacturer’s decision to fully integrate the MES/MOM, preferring instead to wait until manufacturing revenues were sufficient to proceed with the capital purchase.

It was all of a sudden when the Aerospace manufacturer was requested to produce higher volumes, to start supplying parts in only one (1) week; and therefore the MES/MOM software had to be implemented and operational across all four (4) assembly lines as soon as possible.

Once integrated, the next step was to configure the system, taking into account a new workforce with little to no experience in Aerospace parts manufacturing, who were set to start once the system was operational. The MES/MOM system had a significant responsibility to fulfill and was being relied upon as the integral aspect of the project’s success. The challenge was to guide the line operators step-by-step and error-proof in real-time so absolutely no bad parts would be produced and reach the end customer.

Solution

The quick integration and configuration of the plant floor management system was possible given the turn-key nature of the MES/MOM software, which is accessible from any web browser on any computer, tablet or Smartphone. The client was extremely relieved and impressed when they saw the system installed and operational within four (4) days, i.e. an inexperienced workforce was producing high-quality ‘safety critical’ electronics within a week.

The solution was to scale-up the proven MES/MOM system in order to ensure plant-wide error-proofing in all processes on the assembly lines, be it by tool or device, or human. The manufacturing execution system contributed to an over-all paradigm shift by introducing a culture of ‘full-accountability’ into the customer’s manufacturing operations.

“PINpoint taught us what accountability of process really means, the financial value of that and how to maximize the benefit of the assembly equipment we already owned.”
   ~Aerospace OEM Supplier


The Aerospace manufacturer was able to use the MES/MOM to configure the communications presented to assembly line workers in a way most meaningful to them
, with easy to understand paperless work instructions including pictures, graphics, and videos demonstrating the tasks they are to perform. Line workers were guided step-by-step, with the MES/MOM verifying each and every step for conformity.

The intuitive nature and ease-of-use inherent in the MES/MOM enabled the Aerospace manufacturer to become self-sufficient faster, which is exactly what was needed. The level of control the MES/MOM provided the manufacturer drastically reduced or eliminated the opportunity for a poor quality motor controller to be produced and shipped to the OEM. MES/MOM allows its users to error-proof on-the-fly, with the capability to even ‘physically track’ a product/serial number, e.g. to verify where a defective product is on the line, such as to confirm if it is physically located in a repair work station, or not?

In addition to the rapid integration, line worker education, and process verification, the MES/MOM steered the customer towards a future path of maximized or optimized manufacturing operations. The ‘Production Analytics’ program included in the MES/MOM is a powerful continuous improvement tool; producing thorough reports via multi-dimensional database searches.

The analysis of the data being generated from all the processes is invaluable manufacturing intelligence to the discerning analyst and only leads to manufacturing optimization. Reports can be output to display a variety of metrics, and preloaded reports were included, although the customer was able to modify those, or create new search queries and save any as ‘favourites’, including the ability to schedule or create recurring reports which are saved daily for review at a certain time. The user was able to report on KPI’s, OEE, TEEP, number of defects, downtime, over cycle situations, man hour losses, and much more.

MES/MOM Software

The MES/MOM software has been developed since 1997 and it continues to be evolved and pushed-forward by leading manufactures. Thoroughly proven it is in use daily around the world in multiple languages by leading automotive, aerospace, heavy machinery, agricultural, and power sports vehicle manufacturers. The software is meticulously designed and tested to ‘Information Technology Infrastructure Library’ (ITIL) standards before any official version release.

Headquartered in Burlington, Ontario, PINpoint services industry internationally from their offices in Canada, the United States, and China. For more information please contact 905-639-8787sales@pinpointinfo.com or visit the website http://pinpointinfo.com/solutions

Conclusion

The Aerospace manufacturer was able to achieve their goal of a plant-wide integration of the MES/MOM solution, and use the system to guide and empower inexperienced assembly line workers to build sophisticated electronics to the highest quality standards. Due to the ease-of-use of the MES/MOM and its WYSIWYG usability the customer was enabled to become self-sufficient sooner.

MES/MOM introduced full-accountability into their manufacturing operations, and provided ‘integrity of process’ by delivering a process control system that managed all aspects of production. The MES/MOM instilled a closed-loop of accountability and delivered the required results every time.

The speed in which the MES/MOM system was implemented and operational was touted. Within four (4) days the customer was manufacturing defect-free electronic motor controllers across all assembly lines. This allowed the Aerospace manufacturer to gather quality and process data right away in order to further fine-tune processes. MES/MOM made “continuous improvement” an unending practice and to date continues to help evolve the Aerospace manufacturer’s business.

RELATED LINKS

Interactive Presentation: https://prezi.com/adp9dhp3vgn0/why-pinpoint-manufacturing-execution-system-mes-manufacturing-operations-management-mom-solutions/

Production Analytics Demo (Video): https://www.youtube.com/watch?v=inDK_yAuGgs

WHITE PAPER: Maximizing Error Proofing in Manufacturing with MES/MOM Controlled Assembly Tools

Introduction / Summary

This document summarizes the error proofing solution a leading heavy machinery manufacturer implemented and standardized on in order to greatly reduce product defects due to improperly fastened bolts in transmission systems. Electric assembly tools called nutrunners are used by assembly line workers to fasten bolts to a predetermined torque measurement (see Figure 1.).

Their decision to implement a manufacturing execution system (MES) or manufacturing operations management (MOM) software to both ‘monitor’ and ‘control’ all aspects of the assembly tools and line worker processes yielded unprecedented results by reducing bolted joint failures and Warranty claims by 94%.

error proofing

Figure 1. Fastening application with
electric pistol grip nutrunner.

Background / Problems

The heavy equipment manufacturer struggled for years to solve a major problem they had where products were leaving the factory and entering into service with improperly set bolts in the vehicle’s transmission system. These defective products inevitably lead to an increase in Warranty claims. The losses and waste in time and expenses as a result created an urgent call to action to remedy the situation.              

Initially the manufacturer had invested millions of dollars into the latest electric nutrunners, controllers, and associated integration costs. The electric fastening assembly tools specified were to monitor all fastening operations in order to identify defects and repair them before the machines entered service. One (1) year after the implementation of the new assembly tools the customer regretfully reported that there were no measureable improvements in the number of bolted joint failures.

The reason the new nutrunners did not reduce bolted joint failures was due to loop-holes in the system itself. The modern fastening tools did contribute new features which in theory were to ‘capture’ any defects, i.e. if a certain torque (Nm) specification was not met, or number of rotations, set angle, etc., then the system was to record and alert line workers and supervisors of any issues. The system fell short in that it could be bypassed or ‘tricked’ by line workers into thinking a job was completed successfully when it was not.

Solution

The solution was to integrate a manufacturing execution system for error proofing all processes on the assembly line, be it by tool or device, or human. Further, the system contributed to a paradigm shift in that a culture of ‘full-accountability’ was born into the customer’s manufacturing operations.

PINpoint MES/MOM provided the customer a web based ‘configurable’ plant floor management system with the added-value of integral manufacturing optimization features. The MES/MOM filled the void between the customer’s Enterprise Resource Planning (ERP) system and the processes on the assembly line themselves. With the capabilities to both ‘monitor’ and ‘control’ the assembly line processes the MES/MOM ensured no one bit of information or action was unaccounted for. In-turn the process history recorded served to allow for the query of data and output of valuable manufacturing reports which were used to further optimize their manufacturing processes.

Concerning their specific physical problem of bolted joint failures the MES/MOM provided full-control over the electric tool itself, with the capability to ‘lock’ the tool should an installation parameter not be met. Locking out the nutrunners eliminated any chance of the line worker from attempting to pass the defective part. The implementation of the MES/MOM solution yielded instant results as shown (Figure 2.):

error proofing


Figure 2. MES/MOM reduced bolted joint failures 94% and
decreased Warranty claims, as reported by the customer:

“PINpoint’s process management system was instrumental in enabling a culture based on data and facts rather than opinions and guesses. This culture change has enabled increased efficiency and decreased warranty spend, previously unachievable in multiple manufacturing facilities around the world.”

~ Major Industrial Equipment Manufacturer


Since the MES/MOM is configurable the Process Engineers had the flexibility to set the installation parameters as required, e.g. if the first attempt at setting a bolt failed, that is the tool output a torque or angle measurement not in accordance with the set tolerance in the software – the MES/MOM can then be set to allow for a reversal of the tool, and then for another attempt; should the second or even third attempt fail, then at that time the tool may be locked out and an alert raised. The programming of the MES/MOM is flexible, easy and familiar in a drag-and-drop or WYSIWYG user interface; it is as simple as opening a website browser from a laptop/Smartphone, making the change and hitting ‘save’ – all in real-time.

Above the capabilities to monitor all processes and control devices, the MES/MOM serves to first confirm if even there is a line worker present at the station; and who that person is? The MES/MOM verifies line worker credentials before any work instructions can be provided or tools enabled. Each line worker or manager (user) of the system is provided with her/his own login and password. When the worker arrives at the station to begin the shift she/he logs in and is met by the first instructions which may be to verify whether they have completed a training course, for example, or have achieved a required certification to do the job? Only once the worker is verified may the process continue; the system may next present work instructions, or a quality alert, message video, or any instruction as required.

The MES/MOM over-sees all aspects of the production process and is therefore error proofing and detecting and raising alerts of mistakes as they occur; as issues happen the system is capable of sending an alert to a manager with the latest Andon software technology already built in. Textual, graphical, audio and video alerts can be sent via email/text, stack lights, public address systems and on large screen displays.

Error Proofing Software

PINpoint MES/MOM software has been developed since 1997 and it continues to be evolved and pushed-forward by leading manufactures. Thoroughly proven PINpoint is in use daily around the world in multiple languages by leading automotive, aerospace, heavy machinery, agricultural, and power sports vehicle manufacturers. The software is meticulously designed and tested to ITIL standards before any official version release.

Headquartered in Burlington, Ontario, PINpoint services industry internationally from their offices in Canada, the United States, and China. For more information please contact PINpoint at 905-639-8787, aborges@pinpointinfo.com or visit our website http://pinpointinfo.com/solutions

Conclusion

The decision of the heavy machinery manufacturer to implement PINpoint MES/MOM software to both ‘monitor’ and ‘control’ all aspects of the assembly tools and line worker processes yielded unprecedented results by reducing bolted joint failures and Warranty claims by 94%.

Error proofing was maximized since PINpoint ensured defects did not go undetected and encouraged problem solving on-the-fly. PINpoint introduced a culture of ‘full-accountability’ into their manufacturing operations; “…enabling a culture based on data and facts, rather than opinions and guesses.”

RELATED LINKS – ERROR PROOFING

Interactive Presentation: https://prezi.com/adp9dhp3vgn0/why-pinpoint-manufacturing-execution-system-mes-manufacturing-operations-management-mom-solutions/

Production Analytics Demo (Video): https://www.youtube.com/watch?v=inDK_yAuGgs

New to Manufacturing Execution System (MES) Software? Savvy Manufacturers Think Flexibility and Scalability, They Think Long-Term!

Manufacturing Execution System (MES) or Manufacturing Operations Management (MOM) solutions with the capabilities to both “Monitor and Control” the manufacturing assembly line are the cutting-edge in web-based configurable plant floor management systems. If you are new to MES systems and regardless of the size of your operation or complexity, i.e. whether your assembly line today is automated or not, with full-process control or no controls whatsoever, PINpoint MES/MOM need be considered since it is the only MES/MOM designed to match and expand on your production monitoring and process control requirements as your manufacturing operations grow long-term.

Developed over two decades with hundreds of man years invested, PINpoint’s software development team of Information Technology and Manufacturing Process Engineers have evolved PINpoint MES/MOM to be the most powerful manufacturing execution system on the market; now in Version release 4.8 it is by far the most proven manufacturing optimization software capable of managing even the most complex “Make-to-Order” or “Configure-to-Order” manufacturing operations. It is the corporate standard for leading manufacturers in the automotive, heavy machinery, aerospace and power sports vehicle sectors.

Why PINpoint? Regardless of the size of your manufacturing operations, PINpoint is designed to fit. For those manufactures new to MES systems, PINpoint is the ideal starting point or entrance level MES. Essential Production Management-MES (EPM-MES) is PINpoint’s fundamental MES system which is designed as a software foundation you can build on into the future (software versions are continually evolving). Also, included in the entry level EPM-MES product, as well as in their full-process monitoring and control version called Optimized Full Process-MOM (OFP-MOM) is the manufacturing industries next Andon innovation.

PINpoint’s ‘Next-Gen Andon’ is included standard and is a notable value-added feature. PINpoint has evolved Andon manufacturing into the digital age; more than just ‘push buttons’ and ‘stack lights’ Next-Gen Andon is the ultimate production scheduling, tracking, and reporting system. PINpoint has modernized the ability to notify management, maintenance, and other workers of quality or process problems and made it full-proof; it achieves full-accountability in manufacturing by maximizing error-proofing.

Next-Gen Andon is only one of the many powerful software programs included standard in the base EPM-MES version. It and all the other software programs are easily accessible in a drag-and-drop / WYSIWYG user interface; simply open up a website browser on any laptop, tablet or Smartphone to configure your assembly line, schedule production, track products, access manufacturing reports and more. PINpoint EPM-MES allows manufacturers to:

  • Create Work Orders, or import them seamlessly from your Enterprise Resource Management (ERP) system.
  • Schedule Production, set TAKT time, Goals Planned Actual (GPA), monitor and report on Overall Equipment Effectiveness (OEE).
  • Verify Production, interface with line workers, confirm qualifications, progress, catch defects as they happen; control devices, e.g. lock out a fastening tool if multiple errors occur and send an alert.
  • Track Products or serial numbers in real-time, right down to their physical location on the assembly line.
  • Manage Andon, display easy to understand information on large screens with text, graphics and video; and send critical alerts to email/text.
  • OPTIMIZE with provided Production Analytics Manufacturing Intelligence.


For larger or more advanced manufacturing enterprises with full-process controlled assembly lines PINpoint recommends its’ Optimized Full Process-MOM solution. OFP-MOM’s all-encompassing manufacturing execution capabilities allow for the paperless manufacturing management and process control of even the most complex ‘Make-to-Order’ or ‘Configure-to-Order’ manufacturing lines. From Work Order creation to Finished Product, regardless of the number of products or serial numbers, or process steps (including sub-assemblies), you can see and manage all aspects of the operation in real-time. And given ALL of the manufacturing data is recorded and accessible via a multi-dimensional database, real-time Manufacturing Intelligence allows for timely manufacturing optimization via viewable/printable reports.

 

Manufacturing Operations Management | Manufacturing Execution System

Headquartered in Burlington, Ontario, PINpoint services industry internationally from their offices in Canada, the United States, and China. For more information please see the ‘Why PINpoint?’ presentation here:https://prezi.com/adp9dhp3vgn0/why-pinpoint-manufacturing-execution-system-mes-manufacturing-operations-management-mom-solutions/# or please feel free to contact Anthony at aborges@PINpointinfo.com.