The car manufacturer has installed the product of your company. After a year the product has been found defective.
If you had TraceUp! you would not have to attend in multi-million dollar service charge.
The main task of traceability is to provide information related to the origin of the products or components in the production process. Monitoring of process parameters for each technological operation allows to capture quality drops on individual components as well as to detect faulty delivery from supplier.
In case of any complaint, traceability allows identification of defective product, precise indication of other products from the same batch to counteract by repairing or removing them from the market.
1. BOM 2. Stored part with parameters 3/4. I/O signals 5. Stored part with unique common ID 6. Current reference, BOM 7. Unique common ID broadcast
The components involved in the production process are uniquely identified, so that machines are able to identify them during technological operations.
TraceUp! software reads the codes from the components and stores them in the database along with the technological parameters. Data is stored on a TraceUp! Central Server where the components are joined together, which enables later access to the product data, its components and parameters.
TraceUp! Central Server Applications allows you to search for a product and its components based on any production or identification parameter.
TraceUp! System elements:
The components that go into individual technological operations must be marked. The method of identification depends on the needs, eg the durability of the marking. This method can be different for different technological operations. TraceUp! can use bar codes printed on stickers, RFID chips or laser-fired DMC codes.
During the production process, the components are identified for each operation. The identity moment and the number of components depend on the technological operation, eg two components are identified in the assembly process. For identification purposes, TraceUp! uses devices such as bar code readers, RFID readers, DMC camera or DMC mobile scanners.
Adaptation of technological processes and machine data integration is critical, requiring cooperation of the Customer, machine suppliers and the implementation team. Changes in process technology enables full traceability protection, ie, identifying components at the right time, blocking the use of defective components, preventing non-conforming components (BOM incompatible components), and retrieving process parameters at the end of the operation. Communication is via PLC or I/O card.
TraceUp MIP (Manufacturing Integration Platform) communicates with the machine, identifying devices, gets technological parameters, communicates with MES and TraceUp! Central Server, and manages the machine process in complex handshaking (setting/retreiving I/O signals). In addition, MIP visualizes the process operations, informs the operator in case of errors and stores data in local DB if the connection to TraceUp! Central Server is temporary unavailable.
TraceUp! Central Server stores data from all MIPs. The TraceUp! Search Application can search for products/components by DMC code or the value of any technological parameter in the selected range. The TraceUp! Report Application allows to create graphs of parameters over time. TraceUp! Plant View Application visualizes the layout of the line and presents machines operations information (Trace/No trace) with the number of processed components.
In addition to integrating with the machines, TraceUp! can be integrated with the MES system - to retrieve a current reference and/or ERP system - to download current BOM versions.
The implementation of traceability involves the preparation of detailed design documentation in cooperation with the Customer and machine suppliers.
TraceUp! Simulator Application simulates machines and devices in a virtual environment.
The simulator allows you to map any operation performed by the machine (eg PART READY signal) or other devices (eg DMC camera). TraceUp! MIP Software can be switched to simulation mode and communicate with virtual devices instead of the real machine.
TraceUp! Simulator allows to prepare control processes before starting the machine programming.