Manufacturers must ensure the quality of their products before they are shipped. If a sub-assembly part arrives at a station during final assembly and does not meet fit for use quality criteria, the situation will result in return or quarantine. Customer satisfaction is also impacted when issues result in line downtime or increased cycle time on the assembly line. Matrix Automation’s quality verification systems help manufacturers ensure the quality of the parts they ship to their customers.

Benefits:

• Improved process verification leading to improved quality.
• Substantial cost savings
• Reduction in warranty costs
• Decreased scrap

Challenge:

Matrix Automation working with your team will identify and implement solutions to eliminate costly quarantines and negative customer satisfaction as a result of component quality issues. Reliable verification is particularly challenging in many areas of automated and hand assembly processes. Many existing approaches yield inconsistent and unreliable results, in many cases even failing to detect the basic absence of a critical component. When defects occur as a result of an unseen component, many assemblies could be processed before the problem would be identified and rectified, resulting in wasted cycle time and quality spills.

Correct assembly is imperative for all sub-components to be joined together during final assembly. Sub-components with defects will impact further assembly cycle time and yield. In some cases, subtle defects made it through final assembly and are only detected by end users once the vehicle is in use. Components with defects such as missing or improperly secured components may eventually lead to vibration loosening fasteners causing inefficient performance and ultimately resulting in a costly warranty repair.

Matrix Automation solutions provide full integrity verification in real time that can minimize or eliminate these challenges.

The most advanced analysis, traceability & process management software for manufacturing

ProductionWare software transforms manufacturing production data into real-time actionable information. It collects and stores information from the shop floor and provides the most advanced analytics to help you quickly make decisions about critical issues.

Our Customers rely on ProductionWare to:

• Provide automated traceability across the production floor
• Deliver evidence of quality conformance
• Conduct selective recalls
• Improve and control manufacturing processes

Get Complete Traceability

ProductionWare software can collect information from as broad range sources on the production floor. Collecting data from systems ranging from test instrumentation to PLCs, ProductionWare stores serial numbers, dates, shift, time, sub-component information, machine performance, details of the operations and complete process data. Its advanced analysis tools also make it easy for manufacturers to use and manipulate the data collected when necessary. For complete part and process traceability, no software beats ProductionWare.

Provide Evidence of Quality Conformance

If creating reports is a manual process that takes days or weeks, ProductionWare can help. It drastically reduces the time it takes to produce compliance reports requested by management, customers and regulators. Instead of dealing with hundreds or thousands of individual records, ProductionWare brings them together and lets you create the documentation to prove the parts leaving your plant meet set standards.

Conduct Selective Recalls

Armed with ProductionWare, a manufacturer can respond quickly to a potential recall situation and limit its impact. Through its analysis tools ProductionWare helps identify the cause of the issue using the archived data and trace it to the specific parts affected. The results can be dramatic: in several cases, ProductionWare customers reduced a recall from thousands of units to less than ten. Manufacturers can not only protect their reputations, they can also save millions of dollars. In fact, just one use of PRODUCTIONWare for a single recall or quarantine situation delivers immediate pay-back.

Improve and Control Processes

It is easier to control a process rather than the results of a process. Whether it’s meeting Lean Manufacturing goals of zero waste, increasing quality or optimizing yield, manufacturers often struggle with improvement initiatives because they lack visibility into their processes. ProductionWare provides the ability to store historical production data and quickly access and analyze it. Users can identify the root cause of defects and bottlenecks, determine strategies to increase throughput and accelerate the launch of new lines.

• Detect even the smallest manufacturing defects: Analytical tools make it possible to find subtle defects that other manufacturing quality solutions regularly miss. Part and process issues are addressed before the part moves further into production.
• Measurement of process repeatability and compliance facilitates quality compliance reporting and provides confidence in the manufacturing process.
• Rapid build-out of new stations & quality specification: The availability of data-derived specification for a well-behaved process allows rapid build-out of new stations and lines and rapid convergence on quality specifications for new installations.