Adding Value to Online Testing
- By /
Umesh Chavan, Solution Architect
22 May 2017
Customer is always demanding on quality, timely delivery and cost effective products. Digitization of the process can help to improvise product quality inspection process. There are several reasons for a manufacturing industry to implement digitizing this testing process. We need to take several aspects under consideration, viz:
- Failure history with reasons
- Operator error
- History maintenance
- Robustness of the test system
- Configuration control errors
- Test equipment calibration
Let’s see a few examples:
One of the major engine manufacturer performs leak testing of each engine block. They have to keep record of the testing. A separate device performs this testing. The operator records these test results in a logbook. This method has all the shortcomings of a manual process like inaccuracy, incompleteness etc. IIoT can automate the testing thus providing complete, accurate and consistent data every time as well as build traceability. The testing data is stored in a server against the serial number of the engine along with the timestamp, and can be retrieved whenever required.
2.Improve Test Efficiency:
One of the major valves making company has product cycle consisting of 7-8 tests. A test cycle records these parameters for all the valves being manufactured. This cycle testing takes 8-12 hours which include different temperature and pressure testing. Analogue sensors installed to record the values. Therefore, the system can only give the result after all tests are carried out. By installing digital sensors it is possible to get all data in real time and by implementing proper validation system, operator can get the test results in real time. So test which is failed can be identified and stopped at appropriate time. This will help to improve utilization of the system as results are getting in real time instead of being reported after the tests are performed.
3.Analytics on History:
Analytics on History – A company working on precision machining has multiple CNC machines. It has test equipment installed on each machine. After each CNC cycle, the operator has to test the finished product on test equipment. All the test result data is stored in equipment memory card, which in-turn needs to be copied in another validation tool. This tool validates the data and allows the part to move for further processing. This process involves lot of manual intervention, which affects the efficiency.
These test results are not recorded if there is any problem in the CNC machine. Digitization can help record the test result data at the same time when test is executed. Similarly, the test failure data can be used to analyse and improve the machine/operator efficiency by doing corrective actions like maintenance or training.
Above examples emphasise the significance of digitisation in the testing and inspection processes, which can help, improve their efficiency and save a lot of time and money.
Please get in touch with us to know more about such solutions and we shall be delighted to help you gain more from your automated processes. Please visit our website www.aiplindia.com for more details