CIQ 3.0 QUALITY DATA MANAGEMENT SYSTEM

Transcription

1 CIQ3.0QUALITYDATAMANAGEMENTSYSTEM OPTIMIZE MATERIALS USAGE WHILE SECURING SUPERIOR QUALITY LEVELS, ENSURING PROPER DOCUMENTATION ANDRECORDSMANAGEMENT

2 Today, a wide range of inspection technology is available, and cable manufacturing machines are frequently fitted with measuring devices. However, these instruments are very often specific to one particular machine, which means that measurements are made in separate quality islands. Clearly, maximum benefit from the data generated by these individual measuring devices is only achievable if such quality islands are connected together through the company network, allowing you to get an overall view of manufacturing performance. Specific for the cable industry (length and time related) Central data storage and global evaluation Open system (data exchange with ERP, MES, ) Modular design providing a fullycustomized and efficient system The CIQ networks all measuring and testing devices into one common system and stores all the acquired data in a central data storage / common repository. This enables all the entities involved in managing the production flow to have direct access to the process and testing data practically in real time. CIQ (Computer Integrated Quality management system) is organised in modules allowing a perfect adaptation to your specific requirements: QUALITY DATA ACQUISITION (QDM) PROCESS DATA ACQUISITION (SoftDLC) EVALUATION AND REPORTING (QDM) ADDs ON Optimal production control and reduced scraps No more expensive double tests or, on the contrary, missed tests Total quality documentation Reduced planning and testing effort, setting time and risk of human errors A complete quality data storage for process improvements A coherent, unified system for maximum production efficiency

3 PRODUCTION: PROCESS DATA ACQUISITION You want to drive the process cost both effectively and efficiently. Therefore you need reliable and complete information in real time. SoftDLC is the CIQ module dedicated to the process data acquisition and monitoring. Continuously capturing the process data directly on the production floor, monitoring the process and identifying the trends in near real time allows you to drive process cost savings. Through on line capture and display of the process data, trends can be recognized at an early stage in the production process allowing you to proactively intervene and take any necessary corrective and preventive actions. In addition, early warning systems, based on reliable and complete information, let you prevent defects before they occur. Alarms are transmitted to the involved people through different configurable methods. Only flawless material leaves your factory Savings by reducing scrap thanks to corrective actions before defaults occur Online monitoring, remote view, and alarms, also from your office Continuous capture of data, parameters and events related to the process Data recording based on time and cable length Improvement targeting based on information from statistical process control Clear instructions to the work floor concerning machine set up and ERP information

4 INSPECTION: QUALITY DATA ACQUISITION You want to consolidate and evaluate the multiple quality data scattered throughout the different quality island and inspection platforms. QDM is the CIQ module dedicated to data acquisition, evaluation and reporting. QDM cuts testing and evaluation efforts and provides a sound basis for efficient production processes and optimized material use. The QDM has been designed taking foremost into consideration the specificities of the cable industry. It measures length related parameters, and is compatible with the most commonly used cable measuring and testing instruments. In addition, it is suitable for a wide variety of electrical and mechanical cable testing procedures, and is fully aligned with the applicable standards and test specifications. All data processing is performed on the local network without requiring any external (expensive) computing system and/or time The results may be printed, stored as PDF files, or sent as s. It is also possible to create data files for Office products such as Microsoft Excel SQL Super Evaluation module ADO, QDBC Perform tests in all locations (production, laboratories, test stations ) Generate quality related documents (reports, labels, certificates ) Compute data and automatically displays the results Archive raw data for SPC, traceability or potential future needs

5 LABORATORY: QUALITY DATA ACQUISITION In addition to the checks performed in production, it is crucial to conduct laboratory tests, for example for new product validation. Although the product development and maintenance functions are not directly involved in the manufacturing flow, these departments play a key role in ensuring product quality. The CIQ offers specific additional modules to effectively carry out the tasks related to product development & maintenance. U A Centralised data acquisition under a common format whatever equipment is utilised. DRES: Defect Recording and Evaluating. To record and evaluate defects detected during and after the production process TYPLAB: Type Validation and Specific Laboratory tests. To perform and administrate laboratory tests MEC: Mechanical Cycling Test. To perform and monitor performances during long term tests (e. g. bending tests, drag chain tests) DMS: Distributed Monitoring System. To acquire, display and store measurements in different locations (e.g. heating cabinets) And more

6 OFFICE: NETWORKED QUALITY MANAGEMENT You want not only to ensure the product specifications, but also to improve your processes by optimizing your production and tests to boost your yield! CIQ manages all the data acquired through different test locations. It offers immediate access to the whole quality data and an easy way to issue documents accordingly. CIQ is not only designed to verify the product specifications, but also to highlight potential savings by identifying contingent fields of improvements. TEST PLAN CREATION Test specifications and the deriving test orders are the basis for specific and detailed tests, reports and further evaluation steps. All parameters, limits values, formulas, master data, reports, quality charts etc. may be defined in the office already. Work instructions and drawings may be inserted for the operating personnel on the production line. QDM manages the inspection tests according to your test plan. It makes sure that all required tests are realised and provides the operator with the right information at the right time DATA STORAGE Keeping all raw measurements is almost impossible with the current products on the market (especially for the process monitoring and the HF measurements) due to the number of individual values. QDM stores all raw measurements making possible immediate or further analyses and traceability. Data, test plans and test orders can be archived within the system or on external storage media, such as CDs. REPORTING QDM module can be utilised in the shop floor as well as in the office. QDM accesses the centralised storage to issue labels and report, but also to consolidate evaluations. Results can be printed, stored in pdf, send by or exported EVALUATIONS QDM module manages all the quality data acquired through different test locations and production lines. All raw data are available for evaluation at any time. Thus, all test data of a cable can be collectively evaluated and printed. 100% backward and forward traceability is feasible with appropriate filters. QDM can provide quality charts, periodic reports, product manufacturing cards and more to easily identify contingent field of improvements Test reports and labels during the process Test certificates and consolidated test report for your customers Quality charts and graphical representation to enable improvements Daily and weekly reports Product manufacturing cards Individual cable overview

7 CIQ 3.0 : AN OPEN SOLUTION Your ERP and/or MES have limited capabilities in managing the quality data. Nevertheless you want to have a complete data cable management system. CIQ is an open system; therefore it enables data exchange with other systems and data bases, as well as export and import of data of most existing format. AESA Cortaillod has worked in close partnership with companies specialized in cable manufacturing to offer professional, integrated IT solutions. The CIQ provides a unique, highly effective solution which can be interfaced with the most commonly used ERP or MES, for example. ERP / MES Today, several companies offer "turnkey" solutions supporting cable management processes through IT applications networked over the company s LAN. These solutions, which are often complex in structure and involve quite heavy investment, are designed for general purposes and cover most of the central functions common to various industries. However, for the manufacturers of electrical cables and wires, the situation is particular as most of the data to be processed are not related to quantities, but to the cable length, and this specific type of data cannot be handled by any ERP. This means that for electrical cable and wire manufacturing, specialized functional modules are required to complete the quality management toolbox. REPORTING CIQ 3.0 is a open system containing various open interfaces for data exchange. Due to its wide range of different interfaces, CIQ 3.0 can be easily integrated into existing EDP structures. Its multiple interfaces include: Measuring & inspection systems Other ERP systems Creation of outputs in different file formats Integration of existing documents and files Import from and export to SQL databases communication via VPN / Internet and Intranet Unique system combining state of theart cable and IT know how Turning around the limitations of the ERPs and MESs in term of CAQ while having an interconnected solution The user himself can define which data are exported or imported and in which form Interfaces with measuring and inspection systems Data exchange with other ERP systems Creation of outputs in different file formats Integration of existing documents and files Import from and export to SQL databases Communication via VPN / Internet and Intranet

8 REFERENCES AESA SA Chemin de la Plaine 7 CH 2013 Colombier AESA GmbH TBG TechnologiePark Bergisch Gladbach Friedrich Ebert Strasse D Bergisch Gladbach T F aesa@aesa cortaillod.com cortaillod.com