Software
From NOK to OK: STIWA optimizes rework
Due to the targeted provision of data, processes can be stabilized in the long term.
Due to the targeted provision of data, processes can be stabilized in the long term. Outliers therefore can be detected and spring-cushioned quickly. If errors still arise in the production process, STIWA ensures the integration of rework stations in the STIWA control station since many years. As of now, with AMS analysis-CI rework comprehensive analysis options are available live at the HMI.
Rework is a measure to make non-conform products (NOK) conform (OK) again via subsequent processing so it can be delivered to the customer. Fundamentally the avoidance of rework is the uppermost goal of production. But this is getting more and more difficult, explains Alexander Meisinger, Sales Manufacturing Software at STIWA Group: “Technology leaders produce at the limit of what is technically possible. The underlying processes and dependencies are getting correspondingly more complex. The rising customer requirements for precision and accuracy increase the risk of faulty parts in the process. To avoid rejects or save NOK parts and components, the professional data-based rework, additionally to structured process analysis therefore gains more and more importance.“
STIWA optimizes rework
At STIWA the rework station can be easily integrated into the STIWA machine control center AMS Zpoint-CI. The configuration of rework goals, rework actions or special trips is therefore a lot easier. Reasons for error, measured values, batches information, process curves etc. are displayed automatically and thus enable rapid decisions in the selection of rework actions. With rework analysis these records are directly linked to the HMI data from Analysis-CI. This way, for instance the question can be answered what rework actions for which problems have led to success or which components need rework most frequently. Another analysis scenario are changes after double checks. They provide information about the reliability of test stations.
Sustainable cost reduction
AMS Analysis-CI Rework raises the quality of the rework long-term and sustainably. The savings can be quantified well, according to Alexander Meisinger: “For a machine with 1 mil. produced parts and machine sales of approximately 100 mil. euros per year, the reduction of rejects including rework from 5 to 2% amounts to savings of approximately 4.5% of the machine sales already in the first year - in consideration of all production costs.”