A strategic partnership between an electronics manufacturer and SPC software house has resulted in a system that offers substantial improvements process management and improved productivity.
A strategic partnership between Crane Electronics and Lighthouse Systems has resulted in a leading-edge assembly process management solution. Crane's expertise in torque measurement and data collection, combined with Lighthouse Systems' sophisticated SPC software, creates a formidable alliance, and the resulting system offers new opportunities for process management. Crane and Lighthouse joined forces to meet the demands of a leading automotive manufacturer, seeking to make substantial improvements to their process management in search of ever greater quality and improved productivity.

The system is equally adaptable to other manufacturers with similar goals.

System inputs are provided by data collected on Crane's TorqueStar Opta.

Utilising the operator friendly audit scheduling software (Advanced Storage module), data is readily collected from compatible transducer devices.

These include the CheckStar rotary torque and angle transducers and Crane's range of durable wrenches, all of which are independent of the point of load.

This results in greater repeatability and less chance of operator induced errors.

'Plug and Play' technology assists further in ease of use, ensuring the correct tool is used for pre-defined jobs, recognising the connected tool in quick measurement modes, and recording the tool serial number alongside time and date stamped readings in the on-board memory.

A simple routine on the Opta enables 'cause and action' flags to be recorded against readings for grouping and analysis of common assembly problems.

All relevant data is viewable simultaneously on the well laid out display which incorporates large characters for the main torque value.

TorqueStar Opta can communicate with the PC environment via Crane's OptaComms utility, enabling bi-way communication for programming of the Opta and uploading Opta programs and recorded data.

However, the Lighthouse powered system builds on this, enabling centralised control and data management, powerful SPC analysis and real time SPC based process control.

The Lighthouse software takes data from the Crane units, performs SPC analysis, and provides a real-time web based information interface for supervisors and management.

Individuals with appropriate access rights can view graphic models of the assembly process on intranet and internet networks - they are not constrained by geographical location.

Operation status is ascertained at a glance through the use of status colour codes.

Out of condition alarms are a key feature of the system, enabling automatic email and SMS alarms to supervisors with automatic escalation routings as appropriate.

For complex assembly operations, the software helps by providing tools to ensure that supervisors fulfil test quotas and complete recording requirements and can also provide reports on supervisor and team effectiveness.

The software provides complete traceability of changes to programming as well as data input.

Historical values are recorded and can be used to generate trend information or incidence of assembly problems.

As a web enabled system, the software has simple deployment across a company's intranet, eliminating time consuming set-up on individual PCs.

The system also interfaces with a company's existing database, such as an Oracle database, for centralised data control and management.