WHITE PAPER | Bringing Data Visualization Forefront in Fastening Operations

Data visualization is integral to any continuous improvement initiative, and particularly in assembly fastening operations it further enhances error-proofing. Essentially data visualization is a term that describes the effort of helping people to understand the significance of data by placing it in a graphical context. Patterns, trends and associations that might go undetected in text based information can be understood easier with manufacturing execution software that puts data visualization forefront.

The ability to present complicated information to an assembly line worker in a meaningful way only adds to the error-proofing goal. Fastening operations in manufacturing are integral to the successful output of quality defect-free products; any bolt or nut not fastened to the specified tolerances of torque and angle are prone to failure, and potentially warranty claims, and safety concerns once in the field. The importance of quality assuring that each and every bolted joint on any product, and especially safety critical products like automobiles, heavy machinery, and airliners for example, is of paramount concern; safeguards must be introduced to ensure no defects ever pass, and those safeguards must monitor and control all aspects of those assembly operations.

Manufacturing execution system (MES) software provides manufactures of any size the impenetrable defence needed to error-proof. For example, at the line station level the MES interface screens or ‘SmartScreens’ are the first protection to error-proof any assembly fastening operation. Line station workers must first log into the system using their credentials; the system then confirms who they are, and whether they are qualified to do the process steps assigned to that particular station.

Once confirmed, the line worker in the example would next be presented with any pending messages or alerts, such as a Quality Alert, which once read would need to be acknowledged by the line worker to the MES system by pressing a button or entering text. Only after all messages and alerts are observed will the MES system give the line worker the approval to begin work, and turn on the tools and devices needed to perform process steps. From that moment forward cycle and/or Takt time begins, with the line worker being guided ‘visually’ by the SmartScreen to complete the assembly fastening operation.

The latest fastening operation data visualization technology from PINpoint Information Systems provides line workers extremely clear directions and visual feedback regarding the progress of each and every process step they are performing. So much so, it has proven time and time again to be able to instruct newly hired assembly line workers with no previous experience to perform complicated tasks; and to be able to do so in a short timeframe due to the guidance provided by the MES system.

Figure 1 below shows the SmartScreen Rundown Detail window. It comprises all of the information required by the line worker to successfully complete the fastening operation. The fastening tolerances are displayed as they were configured by the production engineers (from a website browser on any computer or phone) and are shown as both the assembly tool Controller Limits, and the MES system [PINpoint] Limits creating the flexibility for two (2) levels of defence in verifying the status of the fastening operation. Easy to identify colored areas in the grid represent the tool controller and MES system limits; the fastening operation Torque tolerance in this example is shown as the blue area, with the Angle tolerance shown as the purple area. Where they overlap distinguishes the target or specified Torque and Angle tolerance for the operation, with the green dot (animated and pulsing) indicating what the result was of the bolt rundown operation.

 

data visualization

Figure 1:SmartScreen’ fastening operation Rundown Detail window.

 
In the Rundown Detail window example above, the target Torque and Angle tolerances for the Tool Controller are 0.00 – 8.00Nm and 0 – 8° respectively; with the MES system [PINpoint] Limits for Torque set at 5.00 – 10.00Nm and Angle at 5 – 10°. When the line station worker performs the operation successfully within tolerance, the Status ‘OK’ is indicated in text as shown, but also visually with a flashing green dot located inside the overlapping colored areas indicating the operation was successful and within tolerance limits. If the worker had failed and rundown the fastener outside of the aforementioned Torque and Angle tolerances, then a ‘NOK’ would be displayed as the status, with a red dot, again flashing, but located outside of the overlapping colored areas indicating a failed rundown, or result outside the specification.

An ‘NOK’ status results in a halt to the line worker’s progress, with assembly tools and devices being locked. The MES system may be configured to allow the line worker to try a second or third rundown by reversing the tool and running it down again, or not; the system is completely configurable, so manufacturers can decide exactly how it is they deal with the defects unique to their products and manufacturing operations. In this case the issue with the defective part could be resolved in different ways, depending on the situation; i.e. perhaps the line worker is able to reverse the tool and attempt another rundown within spec for an ‘OK’ status, or maybe Line Supervisor interjection is necessary? If so, help is available immediately when the line worker presses their SmartScreen andon help button; and regardless of the scenario, once the Line Supervisor is involved she/he are able to make the decision on the next steps, such as re-routing the defective product to a repair workstation.

The use of data visualization on the assembly line only strengthens the manufactures ability to full-proof their error-proofing strategy. From the line workers and supervisors point of view, the system is their guide to doing a good job on time. The MES connects all people and machines into a monitoring, process control, and reporting system that tells you, and your team, how they and overall operations are doing at any given time. The motivation gained by the manufacturing team not only makes for a more efficient factory producing quality products, but creates an atmosphere and culture of people who want to do better together and grow.


DATA VISUALIZATION SOFTWARE

PINpoint Information System’s manufacturing execution system (MES) software is meticulously designed and tested to ‘Information Technology Infrastructure Library’ (ITIL) standards before any official version release. PINpoint’s andon and MES System software have been developed since 1997 and continue to be evolved and pushed-forward by leading manufacturers.

Thoroughly proven the software is in use daily around the World in multiple languages by leading manufacturers. 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 here:
https://prezi.com/adp9dhp3vgn0/why-pinpoint-manufacturing-execution-system-mes-manufacturing-operations-management-mom-solutions/

MES Systems:
http://pinpointinfo.com/mes-systems/

Andon Communications Software:
http://pinpointinfo.com/andon-3d/

Automation.com Article Source:
http://www.automation.com/automation-news/article/bringing-data-visualization-to-the-forefront-in-fastening-operations

 

data visualization

 

Closing the Loop on Manufacturing Error-proofing with MES

Manufacturers of any size are ever seeking ways to improve the efficiency and quality in their product assembly operations; and it is efficiency and quality in manufacturing that quantify the effectiveness of both the physical actions performed on the shop floor, and the caliber of products produced as a result. Considering that quality and efficiency are the life blood of any manufacturing company, closing the loop on manufacturing error-proofing is not only important but often ignored. All too often manufacturers implement manufacturing execution systems (MES) as an extension of their Enterprise Resource Planning (ERP) system only to realize the MES system they implemented does not actively ‘Execute’ anything.

The assembly line is a chaotic bees nest of activity with both humans and machines trying to work in harmony to complete tasks and produce quality products. The trouble is humans make mistakes, and machines, tools, parts, and devices are prone to fail; creating the recipe for operational inefficiency and poorly made products. Product assembly is further complicated by the nature of humans, i.e. humans can be objective in their decisions, and if driven by pressure (say process step cycle time constraints) may try to cheat the system.

For example, a line worker may be using a fastening assembly tool to fasten a bolt in a vehicle transmission; as they perform the fastening operation they receive a ‘No Good’ or ‘NG’ message from the tool controller since the system detected the specified torque and angle parameters were not met. At this point the line worker would try to remedy or correct the situation by trying to run the tool again, or a third time or more until the system indicates a ‘Good/G’ result. The clear issue in this example is the line worker is able to fix the individual problem she/he is having, and in-turn advance the product (which may be defective) to the next station, and ultimately out of the factory, with no one besides the individual line worker themselves knowing what had happened.

The line worker in the example above was able to make her/his own decision on the ‘quality’ of the fastening operation they performed, and pass the product, without a line supervisor or quality engineer approving it. Further, the error that occurred in the operation was not quantified, i.e. the error may have been on the part of the human action(s) only, or it may have been because of a defective tool, or a defective part. Without this deep level of insight into the problem, a solution cannot be had, and the mistakes will naturally be repeated.

The solution is to introduce a system of full-accountability into your manufacturing operations; to close- the-loop on the chance for any defective products to pass. The method to accomplish the goal is to integrate a software based configurable product with specific capabilities for controlling, enforcing, and documenting all manufacturing processes. An all-encompassing MES system both monitors and controls processes, making it the ultimate manufacturing error-proofing tool because it is responsible for directing the process steps to assemble the product, and to determine whether they are completed in tolerance or not.

MES systems are needed to keep an eye on both the human, and the tool/device results, as well as to stop them in the event a process step specification is not met. To maximize manufacturing error-proofing it is most imperative that the MES system both ‘Monitor’ and ‘Control’ the entire assembly process. The MES system must have the capability to halt operations, or stop individual line workers, and turn off all devices or tools associated with the work station and product assembly progress. Only by fully monitoring and controlling the assembly line can the MES system be effective and full-proof in its’ manufacturing error-proofing operation.   

Fully-monitoring the assembly line starts with first verifying the line worker’s credentials when they login to their ‘SmartScreen’ display at the workstation. Line workers must be qualified to perform the process steps at that particular work station; and they will only be allowed to start or be presented work instructions once the MES system approves it. Once approved the line worker may read the work instructions on the screen and press a button or enter text to acknowledge to the MES system the document was read and understood. At this time a Quality Alert may be presented by the MES, which again requires the line worker to acknowledge the alert was read.

Only after all security, assembly, and quality instructions are seen by the line worker and recognized by the MES as read and understood, does the system allow product assembly to commence, and tools and devices to be turned on. The graphic below (Figure 1) illustrates a typical MES system network whereas all line worker ‘SmartScreens’ and andon communication big screens interconnect to the plant server/MES; any tools or devices on the assembly line connected to the plant network or PLCs connect to the MES system also. The configuration portal is accessed by engineers in the cloud from a website browser on any computer.

manufacturing error-proofing

Figure 1: workers receive assembly instructions from SmartScreen user interfaces; the MES system monitors and controls their progress, and allows for configurability on-the-fly from a website browser.

By actively managing and controlling the plant floor the MES system greatly mitigates the opportunity for defective products to pass. Even line workers with very little manufacturing assembly experience can be employed and lead by the MES system to produce quality products in a short timeframe. MES systems empower manufacturers to realize a continuous improvement strategy they can work with and live with long-term. PINpoint’s MES system for example features a complete toolset of configuration features you can use to create your assembly line and process steps in real-time, and easily from a website browser on any computer, tablet or Smartphone.

It also features production scheduling, plant floor communications, product tracking, and manufacturing reporting tools as well, making it one of the most complete, flexible and cost-effective MES systems to implement and scale up in time as your manufacturing operations grow. Ready out-of-the-box, PINpoint can be implemented quickly and does not require third-party consultation or integration, adding even more value to your manufacturing error-proofing strategy.

Perhaps most importantly the MES system enables manufacturers to become aware of the problems that exist, which is fundamental because one does not know what one does not know, right? It is the data acquired from manufacturing that defines the action steps required to improve the efficiency and quality of the operations; it is the manufacturing intelligence and business intelligence afforded by the MES system that defines your strategy for continual improvement to close the loop on manufacturing error-proofing.

MES SYSTEM SOFTWARE

PINpoint Information System’s manufacturing execution system (MES) software is meticulously designed and tested to ‘Information Technology Infrastructure Library’ (ITIL) standards before any official version release. PINpoint’s andon and MES System software have been developed since 1997 and continue to be evolved and pushed-forward by leading manufacturers.

Thoroughly proven the software is in use daily around the World in multiple languages by leading manufacturers. 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 here:

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

MES Systems:

http://pinpointinfo.com/mes-systems/

Automation.com Article Source:

 

PINpoint MES PRO Makes Manufacturing Flexible, Efficient And Trouble-Free

mes pro

PINpoint Information Systems is leading the way with their web-based configurable plant floor management system called MES PRO. Manufacturers in various industries have already made PINpoint manufacturing operations management software the solution of choice for their manufacturing execution strategies. PINpoint’s advanced system is able to tell you everything about every product you ever built, including the people involved and their qualifications for the job. In order to learn more about their software we sat down with Anthony Borges, Marketing Manager at PINpoint:

mes pro

Q: Anthony, could you provide our readers with a brief introduction to PINpoint?

A: For 20 years PINpoint has been on the leading edge of technology throughout the evolution of Manufacturing Execution System (MES) or Manufacturing Operations Management (MOM) software. Today PINpoint is in use across the World in multiple languages by leading manufacturers who have pushed the advancement of the software forward since 1997.

Manufacturing optimization is the only focus at PINpoint; our lean manufacturing solution is all about eliminating waste, reducing cost, improving efficiency, and improving quality. Our turn-key approach to manufacturing execution ensures customers all the features and benefits of an easy to use, web configurable plant floor management system.

Working with OEM customers like Caterpillar, Navistar, Perkins and Hyundai have confirmed our position as a leader in the industry. PINpoint Andon and MES system solutions have also played a major role at Lear, JCI, AWTEC, Magna, Automodular, Arvin Meritor, Benteler and Hamilton Sundstrand on projects supplying content to leading manufacturers Nissan, Toyota, GM, Ford, Chrysler, and Boeing.

PINpoint’s Andon 3D and MES PRO software are ready for integration out-of-the-box, saving time and money while providing a thoroughly proven lean manufacturing solution. Users of our software today attest to it being a formidable error-proofing system that empowers them to increase manufacturing efficiencies while delivering a positive return on investment.

 

mes pro

 

Q: Could you explain the function and advantages of your MES PRO manufacturing execution system?

A: Modern manufacturing practices demand the flexibility of running many products down a single assembly line while maintaining the quality and efficiency necessary to succeed in a competitive, global economy. This requires a global strategy to monitor and control all aspects of your plant floor processes that can impact quality and efficiency. MES PRO is an out-of-the-box manufacturing execution system that both ‘monitors’ and ‘controls’ all aspects of manufacturing; creating a closed loop of accountability in manufacturing operations.

Plant floor controls is the area most MES systems typically deflect to their local programmable logic controller (PLC) integrator, which typically leads to expensive custom solutions. PINpoint’s MES PRO differs greatly in that it manages the chaos of assembly lines with nothing more than a website browser. It is the industries most proven web based configurable plant floor management system that adopts to specific manufacturing requirements on-the-fly; and it is flexible, and scalable for the long-term, to grow with the manufacturer as their operations expand.

Whether a customer wishes to start with andon, production monitoring or comprehensive plant floor control, one station or an enterprise, PINpoint has a proven solution ready for turn-key implementation. MES PRO allows manufacturers to track products; a configurable strategy that drives granularity of data while providing visibility of your product throughout the entire process. MES PRO creates integrity of process by managing all plant floor activities from the operator to the equipment, creating a solid defense to ensure defective products do not pass.

MES PRO manages all shop floor data, recording and storing it for further analysis. PINpoint MES PRO’s advanced production monitoring generates laser focused data on everything you do on the plant floor while the latest data analytics technology transforms that data into meaningful reports to drive proactive management decisions.

 

mes pro

 

Q: You’ve recently announced the release of Andon 3D; tell us something more?

A: Andon 3D is a cutting-edge manufacturing software which is the industries most evolved for assembly line communications, product tracking, and manufacturing reporting. Much more than traditional andon systems that feature stack lights and push buttons, Andon 3D is able to provide manufactures valuable insight into their manufacturing operations, essential information they need to know on how an assembly line is really running in order to maximize error-proofing and improve quality.

Andon 3D is a tool set that identifies the myriad of every day scenarios that play out on the assembly line; it then provides manufacturers instant visibility of that information. It helps manufacturers visualize every action, good or bad, that has a direct impact on efficiency. Manufacturers can now easily meet their daily demands of quality, efficiency and flexibility with a readymade software solution. Andon 3D is a modern approach to every day manufacturing challenges and it is essential for improving Goal, Planned, Actual and OEE targets.

At the foundation of Andon 3D technology is PINpoint’s Manufacturing Execution System (MES) called MES PRO: a long-term proven web based configurable plant floor management solution. Andon 3D includes many of the features found in the MES system, which makes it the ideal entry to develop your future manufacturing execution system strategy. It includes features like SmartBuild, which Engineers can access by opening a website to visualize and configure assembly line operations in real-time from any computer, tablet or Smartphone.

On the assembly line, station operators interact with their own SmartScreen touch displays at each work station. They provide the line worker info she/he needs to complete assembly process steps, and the timing. It also presents the line worker with Andon help buttons for when issues arise, as when time is running out, in order to call for help to avoid a line stoppage. Please see the image below for additional SmartScreen features.

 

mes pro

 

Q: What are the main benefits for manufacturers?

A: From OEE to Waterfall Reports, operating efficiency is the focus of any good manufacturing operation. PINpoint’s MES PRO and Andon 3D products provide manufacturers the visibility to identify where it is in their manufacturing processes improvements can be made to increase manufacturing efficiencies and product quality.

The problem is that most manufacturing operations management systems lack the sophistication to generate data with the resolution to provide meaningful metrics from the shop floor. MES PRO and Andon 3D put performance metrics forefront for all to see; whether displayed prominently on every operator’s SmartScreen user interface so there is no question as to how work is progressing compared to cycle time; or as meaningful reports as output using MES PRO and Andon 3D’s production analytics database search tools. This allows manufacturers to create customized reports essential for continuous improvement.

 

mes pro

 

Q: What are your plans for the next six months?

A: The year two-thousand and seventeen (2017) marks the second-decade anniversary for PINpoint Information Systems and brings with it many more Industry firsts in manufacturing operations management. Building on our leading fastening operation error-proofing technology, the latest version of PINpoint software 4.12 features a new data visualization tool for assembly line workers. By displaying the Torque, Angle, and both the Controller and PINpoint Limits, station operators have a clear understanding of how they are progressing in their fastening process steps. The image above shows a sample window from the SmartScreen client; it illustrates the current fastening operation’s rundown detail.

Further, PINpoint is excited to announce the release of a cutting-edge manufacturing reporting data visualization system that takes the guesswork out of interpreting manufacturing statistics; it is a manufacturing intelligence and business intelligence tool with the power to communicate continual improvement objectives using video playback. It affords engineering managers the ability to actually ‘play-back’ a summary of production shifts in their website browser, at a selectable speed, to really hone in to see exactly when there was an impact on manufacturing efficiency.

Essentially, it allows managers to drill down in the data quickly to identify the root of the problem. This development eliminates all need to subjective quantification of production problems, and provides real-time feedback of what is really happening on your shop floor.

PINpoint Information System’s manufacturing execution system (MES) 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.

RELATED LINKS

Download our latest Andon 3D product brochure here:
PINpoint Andon 3D Product Brochure

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

Interview Source – SuperbCrew:
http://www.superbcrew.com/pinpoint-information-systems-makes-manufacturing-flexible-efficient-and-trouble-free/

Advancing Error-proofing Via MES System Control

MES system control remains a key factor in the Smart Factory of the future, and the advancement of error-proofing; because error-proofing presents a constant challenge for manufacturers in their quest to produce products with the utmost quality and efficiency.

With the advent of advanced automation techniques, the IIoT and Industry 4.0 concepts, we answer the question, ‘What is the Optimal Method to Eliminate or Mitigate Defective Products Made by Human or Machine?

 

mes system control


The answer is to identify the root cause of the manufacturing problem, and to make the necessary changes to stop those actions or correct those individual process steps that led to the defect. One can imagine the difficulty in performing such an investigation, and the time needed to do so. It requires the analysis of manufacturing data, and whether you have a lot of data or not, the human is still a factor in determining how to manipulate that data into a report that makes sense enough to lead to an improvement.
 
Ideally, the more manufacturing data available for analysis the better; no single bit or process step in the assembly of the product should be overlooked. Including cycle time or Takt, which is also integral to optimally configuring processes. The data should also include the specifics of the human or line worker performing the steps, in order to answer questions such as:

  • Was the line worker or station operator logged in?
  • Was she/he trained and verified to work on those process steps?
  • Were they presented work instructions, or quality alerts; and did they acknowledge reading them?
  • Were there any process steps they performed incorrectly? Did not pass; or took too much cycle time to complete?
  • How did the line worker communicate their issues? Was the andon communications system optimally utilized; and what can be learned from how the line worker communicates problems, and how quickly they are resolved?


The list of possible defect causing actions is endless, especially considering the unique manufacturing operations of every facility regardless of product. The common thread is all manufacturers must make effective actions, right down to the individual process step being done perfectly in order to produce quality products. Integral to this is how you monitor and control all the manufacturing activities on your plant floor.
 
As outlined by ISA-95, the manufacturing activities relating to the individual steps required in the assembly of any product compose level 0, level 1, level 2 and level 3 of the model; with manufacturing execution system (MES) or manufacturing operations management (MOM) activities making up the whole of level 3. It is the MES/MOM level of the ISA-95 model alone that relates directly to the monitor and control of the assembly line and each and every product it outputs. The MES system is responsible for the work flow, or the recipe control to produce the desired end products. MES system control is also essential for maintaining the records or manufacturing data that can be later used to further optimize production processes.
 
Every-single manufacturing activity by human or machine below the Enterprise Resource Planning (ERP) level 4 of the ISA-95 model relates directly to whether a quality product will be assembled or not. The plant floor is where the action happens, where ‘physical’ process steps are completed to produce ‘physical’ products. It is the MES system control overseeing all this that affords the manufacturer the means to produce quality products in the most efficient way possible (in an acceptable timeframe, and with less waste produced). MES system control also affords the manufacturer the means for continuous improvement; because even if you are producing a quality product today, the question follows if you are doing so efficiently or not? The MES system empowers manufacturers to fine-tune cycle time; to make on-the-fly adjustments to process step sequences, and cycle time. Cycle time in itself is a factor in error-proofing, as in the example of a process step cycle time being too short and causing the line worker to hurry and make mistakes.
 
Note that to be successful it is imperative that the MES system be the central hub or nervous system of your manufacturing operations; i.e. the MES system is to both ‘monitor’ and ‘control’ the assembly line. All assembly line devices connect to it including the programmable logic controllers (PLCs), and all humans interact with it creating a closed-loop of accountability. To maximize the error-proofing result the MES system must control both human and machine, with the ability to halt progress and/or turn tools or devices off as needed. This ensures a solid defense against defects being overlooked or bypassed without supervisor approval. It is the only all-encompassing error-proofing solution, and the means for any sized manufacturer to improve since MES system control comprises all aspects of manufacturing optimization, including manufacturing intelligence and business intelligence.
 
The future of advanced error-proofing is by way of MES system control. Leading automotive, heavy machine, aerospace, military, marine and power sports vehicle manufacturers across the World already use the MES system as their go-to tool to do things better, quicker, and with less waste; to only produce quality products efficiently. MES software like PINpoint Information Systems’ solution can now be integrated by any sized manufacturer; there is no limit on the number of users or work stations or assembly lines, or products or process steps – the MES system is designed for the long-term, it is fully flexible, and scalable to expand as manufacturing operations grow.
 
The MES system can be implemented by Engineers in as little as a few days, and full training ensures your confidence in its operation; which is actually simple since the software is accessed from a website browser on any computer or phone. It is an intuitive software with a familiar drag-and-drop interface and WYSIWYG experience. On a daily basis the MES system is the center of operations, conversing as effectively with the ERP system where the orders originate and progress is reported, as with the plant floor where every single aspect of production is tracked, critiqued, reported, and adjusted. It is the configurability of the MES system which makes it any manufacturers ally in their quest for quality and efficiency.
 
MES SYSTEM CONTROL SOFTWARE
 
PINpoint Information System’s manufacturing execution system (MES) software is meticulously designed and tested to ‘Information Technology Infrastructure Library’ (ITIL) standards before any official version release. PINpoint’s andon and MES System software have been developed since 1997 and continue to be evolved and pushed-forward by leading manufacturers.
 
Thoroughly proven the software is in use daily around the World in multiple languages by leading manufacturers. 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

MES Systems:
http://pinpointinfo.com/mes-systems/
 
See the “Why PINpoint?” prezi here:
https://prezi.com/adp9dhp3vgn0/why-pinpoint-manufacturing-execution-system-mes-manufacturing-operations-management-mom-solutions/
 
Automation.com Article Source:
http://www.automation.com/portals/manufacturing-operations-management/advancing-error-proofing-via-mes-control

 

Introducing Andon 3D Error-proofing User Interface

error-proofing

Andon 3D by PINpoint Information Systems is a modern twist on assembly line operator user interfaces. Andon 3D is not your traditional HMI or SCADA, it is an error-proofing solution overseeing manufacturing operations and the actions of the line operator. It operates above or next to HMI and SCADA; and unlike those traditional systems, Andon 3D is the ultimate plant floor communication, product tracking and manufacturing reporting system essential for improving manufacturing efficiencies.

At the foundation of the Andon 3D technology is PINpoint’s Manufacturing Execution System (MES), a long-term proven website based configurable plant floor management solution. Andon 3D includes many of the features found in PINpoint’s MES system, which makes it the ideal entry to develop your future manufacturing execution system strategy. PINpoint includes all the manufacturing optimization tools you need in a turn-key paperless manufacturing solution, starting with SmartBuild. Simply open the SmartBuild website to visualize and configure your assembly line in real-time from any computer, tablet or Smartphone.

Line operators interact with their own SmartScreen touch displays at each work station. It provides the line worker information she/he needs to complete assembly process steps, and the timing. It also presents the line worker with andon help buttons for when issues arise, as when time is running out, in order to call for help to avoid a line stoppage. Please see Figure 1 for additional SmartScreen features:

error-proofing

Figure 1. Andon 3D error-proofing SmartScreen user interface example.


The first order of error-proofing at any station is the verification of ‘who’ is working there (logged in), or not. Immediately the system can determine whether that operator is even qualified to do the tasks at hand; if they are, the system allows them to proceed and provides work instructions.

If we dig deeper we can extract even more details about the efficiency of the work station and line operator. For example, if an operator is not logged in at their work station when a product is available to be worked on, would you not want to know why? Alternatively, if an operator is logged in at their station, and no product is available to be worked on, then why or how did that happen? Only Andon 3D can give you the insight required to identify such time depleting details of cycle time that ultimately accumulate and cause over-cycle events.

All the data or interactions of the line operator with the SmartScreen user interface are monitored and recorded, and can be reported on using Andon 3D’s Production Analytics feature. It is the manufacturing intelligence afforded by the Andon 3D system that leads to the implementation of effective continuous improvement initiatives. All plant floor communications and product data are captured into the PINpoint “Cube” multi-dimensional database, which is manipulated easily in a web browser or by using Microsoft Excel with Production Analytics to report on a multitude of manufacturing operations specifics, right down to cycle-time losses.

Production Analytics gives you valuable insight into where it is your cycle time is going, how it is being allocated, and how it can be improved to the finest detail. It allows you to find out exactly where it is on your assembly line bottlenecks in time are occurring, and who caused them. This vital information allows the manufacturer to take decisive actions to remedy the issue, be it re-allocating cycle time elsewhere, or process steps to another station. Andon 3D is a flexible and scalable error-proofing solution that adapts to your unique manufacturing processes; it gives you the visibility needed to make changes in real-time that impact your bottom line instantly.

Andon 3D Error-proofing Software

PINpoint’s Andon 3D and manufacturing execution system (MES) called MES PRO have been developed since 1997 and continue to be evolved and pushed-forward by leading manufacturers. Thoroughly proven our software is in use daily around the World in multiple languages by leading automotive, aerospace, heavy machinery, agricultural, power sports vehicle manufacturers and more. PINpoint 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 call: +1 (905) 639-8787, email: sales@pinpointinfo.com or visit: http://pinpointinfo.com

RELATED LINKS

Download our latest Andon 3D product brochure here:
PINpoint Andon 3D Product Brochure

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

 

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