Bringing Data Visualization Forefront in Fastening Operations

Data visualization is integral to any continuous improvement initiative, and particularly in assembly
fastening operations it further enhances error-proofing. Essentially data visualization is a term that
describes the effort of helping people to understand the significance of data by placing it in a graphical
context. Patterns, trends and associations that might go undetected in text based information can be
understood easier with manufacturing execution software that puts data visualization forefront.

The ability to present complicated information to an assembly line worker in a meaningful way only
adds to the error-proofing goal. Fastening operations in manufacturing are integral to the successful
output of quality defect-free products; any bolt or nut not fastened to the specified tolerances of torque
and angle are prone to failure, and potentially warranty claims, and safety concerns once in the field.
The importance of quality assuring that each and every bolted joint on any product, and especially
safety critical products like automobiles, heavy machinery, and airliners for example, is of paramount
concern; safeguards must be introduced to ensure no defects ever pass, and those safeguards must
monitor and control all aspects of those assembly operations.

Manufacturing execution system (MES) software provides manufactures of any size the impenetrable
defence needed to error-proof. For example, at the line station level the MES interface screens or
‘SmartScreens’ are the first protection to error-proof any assembly fastening operation. Line station
workers must first log into the system using their credentials; the system then confirms who they are,
and whether they are qualified to do the process steps assigned to that particular station.

Once confirmed, the line worker in the example would next be presented with any pending messages
or alerts, such as a Quality Alert, which once read would need to be acknowledged by the line worker to
the MES system by pressing a button or entering text. Only after all messages and alerts are observed
will the MES system give the line worker the approval to begin work, and turn on the tools and devices
needed to perform process steps. From that moment forward cycle and/or Takt time begins, with the
line worker being guided ‘visually’ by the SmartScreen to complete the assembly fastening operation.

The latest fastening operation data visualization technology from PINpoint Information Systems
provides line workers extremely clear directions and visual feedback regarding the progress of each
and every process step they are performing. So much so, it has proven time and time again to be able
to instruct newly hired assembly line workers with no previous experience to perform complicated tasks;
and to be able to do so in a short timeframe due to the guidance provided by the MES system.

Figure 1 below shows the SmartScreen Rundown Detail window. It comprises all of the information
required by the line worker to successfully complete the fastening operation. The fastening tolerances
are displayed as they were configured by the production engineers (from a website browser on any
computer or phone) and are shown as both the assembly tool Controller Limits, and the MES system
[PINpoint] Limits creating the flexibility for two (2) levels of defence in verifying the status of the
fastening operation. Easy to identify colored areas in the grid represent the tool controller and MES
system limits; the fastening operation Torque tolerance in this example is shown as the blue area, with
the Angle tolerance shown as the purple area. Where they overlap distinguishes the target or specified
Torque and Angle tolerance for the operation, with the green dot (animated and pulsing) indicating what
the result was of the bolt rundown operation.

Figure 1: ‘SmartScreen’ fastening operation Rundown Detail window.

In the Rundown Detail window example above, the target Torque and Angle tolerances for the Tool
Controller are 0.00 - 8.00Nm and 0 - 8° respectively; with the MES system [PINpoint] Limits for Torque
set at 5.00 - 10.00Nm and Angle at 5 - 10°. When the line station worker performs the operation
successfully within tolerance, the Status ‘OK’ is indicated in text as shown, but also visually with a
flashing green dot located inside the overlapping colored areas indicating the operation was successful
and within tolerance limits. If the worker had failed and rundown the fastener outside of the
aforementioned Torque and Angle tolerances, then a ‘NOK’ would be displayed as the status, with a
red dot, again flashing, but located outside of the overlapping colored areas indicating a failed rundown,
or result outside the specification.

An ‘NOK’ status results in a halt to the line worker’s progress, with assembly tools and devices being
locked. The MES system may be configured to allow the line worker to try a second or third rundown by
reversing the tool and running it down again, or not; the system is completely configurable, so
manufacturers can decide exactly how it is they deal with the defects unique to their products and
manufacturing operations. In this case the issue with the defective part could be resolved in different
ways, depending on the situation; i.e. perhaps the line worker is able to reverse the tool and attempt
another rundown within spec for an ‘OK’ status, or maybe Line Supervisor interjection is necessary? If
so, help is available immediately when the line worker presses their SmartScreen andon help button;
and regardless of the scenario, once the Line Supervisor is involved she/he are able to make the
decision on the next steps, such as re-routing the defective product to a repair workstation.

The use of data visualization on the assembly line only strengthens the manufactures ability to full-proof
their error-proofing strategy. From the line workers and supervisors point of view, the system is their
guide to doing a good job on time. The MES connects all people and machines into a monitoring,
process control, and reporting system that tells you, and your team, how they and overall
operations are doing at any given time. The motivation gained by the manufacturing team not only
makes for a more efficient factory producing quality products, but creates an atmosphere and culture of
people who want to do better together and grow.

MES SYSTEM SOFTWARE

PINpoint Information System’s manufacturing execution system (MES) software is meticulously

designed and tested to ‘Information Technology Infrastructure Library’ (ITIL) standards before any
official version release. PINpoint’s andon and MES System software have been developed since 1997
and continue to be evolved and pushed-forward by leading manufacturers.

Thoroughly proven the software is in use daily around the World in multiple languages by leading
manufacturers. Headquartered in Burlington, Ontario, PINpoint services industry internationally from
their offices in Canada, the United States, and China. For more information, please call: +1 (905) 639-
8787, email: sales@pinpointinfo.com or visit: http://pinpointinfo.com/

RELATED LINKS

See the “Why PINpoint?” prezi here:

https://prezi.com/adp9dhp3vgn0/why-pinpoint-manufacturing-execution-system-mes-manufacturing-
operations-management-mom-solutions/

MES Systems:
http://pinpointinfo.com/mes-systems/

Andon Communications Software:

http://pinpointinfo.com/andon-3d/

Automation.com Article Source:

http://www.automation.com/automation-news/article/bringing-data-visualization-to-the-forefront-in-
fastening-operations
Author:
Anthony Borges

Biography:
Anthony offers over a decade of manufacturing optimization knowledge, with an aptitude for solving
problems which increase manufacturing efficiency. He has successfully provided solutions to various
multinational manufacturers involving the latest technology in sensors, laser (detection, measurement,
welding, cutting, and marking systems), PLC, machine vision, microscope, and software solutions.

Keywords:
manufacturing execution system, manufacturing operations management, MES system, andon, andon
system, andon software, error-proofing, lean manufacturing, six sigma, paperless manufacturing,
continuous improvement, quality control, process control, smart factory, industry 4.0,

Abstract / Introduction:
Data visualization is integral to any continuous improvement initiative, and particularly in assembly
fastening operations it further enhances error-proofing. Essentially data visualization is a term that
describes the effort of helping people to understand the significance of data by placing it in a graphical
context. Patterns, trends and associations that might go undetected in text based information can be
understood easier with manufacturing execution software that puts data visualization forefront.