Information tool for production, assembly, and quality control

The FACTS4WORKERS solution provides employees with all information relevant to production, assembly, quality control, and machine maintenance.

Field and area of application

  • Production of components for tools
  • Assembling components into end products (progressive and transfer tools)
  • Quality control
  • Machine maintenance

 

EMO Orodjarna provides tools for the large presses of automotive and aviation customers as well as their suppliers. These tools are produced in small batches in a host of different versions. Employees require all information relevant to the products during the production, assembly, quality control, and maintenance processes. This information should be accessible intuitively to support instead of interrupt employees’ workflow. In addition, there should be the option to communicate important events and create notifications.

The FACTS4WORKERS solution offers the employees of EMO Orodjarna all information relevant for the production, assembly, quality control, and maintenance processes without interrupting their workflow.

Core functionality

Project overview

The database connector offers a visually appealing overview of the production process statuses as well as a display of relevant CAD files. The list of parts is searchable using keywords.

The screen “Part details” offers access to information on metadata, process details, and quality control events.

Documentation

Production malfunctions can be reported within the system using photos and text descriptions. The parts process view offers detailed documentation on the production process, offering employees insight into which malfunctions should be resolved or which parts should be reworked. Employees can initiate a workflow to suggest improvements to more efficiently design the production process. The chat and video functions support employees on their daily activities. Employees can request the remote support of an expert in any situation. In addition, employees can access a range of learning materials and walkthroughs at various education levels. Employees’ own activities can be documented and improved with photos and videos.

Benefits of the Facts4Workers solution

Mutual understanding of daily activities

After

After arriving at work, Ivan first inspects if all parts necessary for his activities are available. Several parts have been stacked underneath the processed cast-iron frame and are waiting for assembly. He searches the workshop to find other parts he needs but can’t find a number of them. Where are they? Who might be able to tell him where they are? As he makes his way through the workshop, he chats with several colleagues who are busy assembling other tools. One of the parts he needs seems to have gone missing. Nobody can provide him with further information on the part, which is why he is forced to request the assistance of other colleagues such as Andrej, his project manager. Ivan is unable to work on his tools and continues work on another tool instead; however, the problem only repeats itself! He requests the assistance of other employees to quickly get an overview of the current state of the tool and the associated parts. After errors are made during the assembly process, it’s often hard to identify who made the mistake, as the information necessary to identify the “culprit” is only stored offline, in the minds of employees.

Before

EMO Orodjarna successfully implemented the new F4W solution, and Ivan just received his personal tablet. When he arrives at the workshop, things look the same as they did before: The tools and parts are ready for assembly. Ivan uses his tablet to check the status of the assembly process. At a glance, he is provided with an overview of the packages waiting for assembly and those that still require parts. He can now start assembling the listed parts. After he is done, he logs his progress in the system. He cannot continue working on the tool, because the next key part is still in production. The system informs him who’s working on the part and when the production process is expected to be completed. Seeing as how it takes too long to wait for the next parts, Ivan decides to start working on another tool. He uses his tablet to report the problem to his team leader and informs him that he starts working on a different tool. This only takes a few minutes even though Ivan has no idea where his team leader is. After starting on the different tool, he again uses his tablet to access information on the new project.

Quality control

After

Ivan is in the middle of a crucial assembly step and notices that the part he wants to assemble deviates from the specified shape. He was only able to notice the error thanks to his long-standing experience, thus preventing the more severe consequences that would otherwise have arisen when testing the tool. With a calliper, he establishes that the part indeed deviates from the illustration; however, he cannot fix this himself. Whenever this happens, he wonders why the quality control processes seem lacking.

Only by chance does Ivan know that Anton produced this part. Otherwise, he would have had to start searching for someone who could help him. He brings the erroneous part to Anton and explains the problem to him in person. He then asks Anton if he can rework the part immediately. Luckily, Anton has some spare time in his usually very busy schedule and starts working on the part in his three-axis CNC milling machine. After the part’s surface is milled into the desired shape, Ivan takes the part to his tool for assembly.

Before

Ivan is in the middle of a crucial assembly step and prepares to start working on the next part. It’s crucial to machine operation that the part complies with the specified dimensions. Ivan uses his tablet to evaluate whether the part underwent the full quality control process. The detail page of the part clearly shows that the part was not subjected to a quality control. He therefore opens the CAD file and uses his brake calliper to compare his measurements of the special part with the displayed dimensions. Ivan thus performs the quality check himself. It turns out that the dimensions are incorrect, but Ivan is not capable of reworking the part himself. He looks up who’s responsible for the part on his tablet. All machine operators involved with the production of this part are shown on the part’s detail view. Ivan learns that he should discuss this matter with Anton. Instead of running through the entire workshop, Ivan uses the “error report” and chat function to document the error and contact Anton, who tells him that it will not be a problem to rework the part within an hour. After Anton completes the part, Ivan quickly assembles it. It’s a perfect fit. Ivan now checks the “quality control” and “assembled” boxes.

Preventative maintenance

After

Marko is struggling with an unexpected problem. A maintenance procedure must be initiated for the laser cutter. The machine gave off a warning that the parabolic reflector is soiled and needs to be cleaned. Marko must partly disassemble the laser head to remedy the issue. The laser cutter is an important machine, and there’s only one of its type available in the workshop. Incoming machine orders pile up. While Marko is busy fixing the laser cutter, Anton walks by as his CNC machine also grinded to a halt – his remote controller stopped working. Marko is stressed out because he knows exactly what Anton’s problem is and additionally knows that it would be an easy fix for Anton himself if he only knew how. While Marko is busy reassembling the laser head, he notices that another part is also damaged and should be replaced immediately. There are no spare parts available on-site; however, Marko knows that he can pick up a spare part directly at a distributor located around 100 km away. He gives the distributor a call and drives over in his own car. He arrives back at the workshop three hours later, assembles the part, and the laser cutter resumes normal operation. However, Anton still experiences issues with his controller. Marko walks over to his workspace and concludes after a quick once-over that an electrical connection in the remote controller terminal is loose. He shuts down the machine and tightens all screw clamps to guarantee proper electric connection. After activating the machine again, he inspects its basic functionalities and concludes that his repair did the trick. Marko immediately notices that the workspace is poorly lit due to a burned-out bulb. An easy fix, there are plenty of replacement bulbs available in the workshop.

Before

The laser cutter gives off a warning that the parabolic reflector must be cleaned. Frank, who operates the laser, takes his F4W smart glasses to scan the QR code on the machine and look up the error in the database. This preventative maintenance procedure is demonstrated in a training video. His colleague Marko prepared a detailed walkthrough as part of the preventative maintenance routine. This gives Frank the confidence to repair the machine himself. While cleaning and reassembling the laser head, Frank notices that another part also appears damaged. He looks up a solution on his tablet and finds out that there are is no information available for this problem, as it has never happened before. He requests the personal help of Marko by pressing the “request for maintenance personnel” button on his tablet. Marko comes over and confirms that the part should be replaced immediately. He takes his own car and drives to a local distributor located 100 km away to purchase the part. After returning at the workshop, he assembles the components and the laser resumes regular operation. Marko thinks that it might be worth the effort to inspect the part more frequently in future, so he adds it to the list of regular maintenance inspections, which the machine operator will now perform once every three months. At the end of each step, Frank – as well as the other machine operators – uses his tablet to work through the recommended maintenance task to prevent unexpected interruptions. Meanwhile, Anton continues producing his parts as usual and his machine works seamlessly. The remote controller is also in perfect condition, because Anton tightened all electric connections after being advised by his tablet to do so. The bulb burned through one week earlier. Anton immediately recognised it but did not need to call Marko as he could work through the simple instructions provided by the tablet himself. At the end of today’s shift, the system requests the cleaning of a liquid filter. After Anton completes the task, he checks the box and marks the process as completed in the system. This gives Marko great peace of mind, as it is quite stressful for him to solve unexpected problems. He can now also focus on his other tasks. From the production side, there is the benefit of fewer malfunctions and less downtime.

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