Mr. Karsten Fischer, Fischer Consulting, GERMANY
Andreas Meyer, AUT-FIT Automatisierungstechnik GmbH, GERMANY
To fulfill the customer requirements concerning pad delivery within six sigma quality range, it is mandatory to control the process parameter and check product properties according to a control plan.
The purpose is to launch an integrated quality control process;
`integrated quality process´ indicates a process, where quality checks are taken in earlier state of manufacturing linen, not only after the final completion;
Manufacturing lines in single piece flow need to use handling- or robot systems to manage the hand over operation from process step to process step; in this configuration it is possible to use hand over- and/or Robot systems to feed additional measurement stations as well.
Dimensional checks of backing Plates or Friction blocks could be done integrated in the material flow direction and within the cycle time/piece to piece time; other checks with a longer measurement cycle time can be realized by doing integrated sampling operation with the assistance of Robot System (for example: Compressibility Ex Post Curing);
In case we detect variances or trends on the product characteristic during process line operation, it would be possible to improve the quality for following semi finishing goods by fine tun the process parameter;
The introduction of an integrated quality system would generate a great benefit under economical aspect!
In the following you will see an overview concerning possible Quality Controls for a process line from molding to assembling;
Press Curing Post Curing thickness scorching powder paint assembling
oven slotting paint curing
Below the process flow diagrams is a list with parameters which could be measured (list is not complete, because every producer has his specialties) and how it would be possible to arrange that kind of measurements between named manufacturing steps;
Manual sampling: manual sampling, manual measurement beside the Line or in Laboratories
Integrated sampling: sampling with robot, automatic measurement
Integrated 100%: 100% integrated Quality control
(Flow diagrams are not shown with this report)
As mentioned before: the challenge is to do quality controls in early state of manufacturing!
I´m looking forward receiving new information and concepts on EuroBrake 2020 concerning:
New measuring methods (optical dimension measurement system)
New measurement positions inside manufacturing flow
Possibilities to keep process date stable for each process step (process capability)
Overall Process Data management system for complete process line
Overall Quality data report for all measurements