Ensuring Quality Control in Distributed Manufacturing

In distributed industrial companies, where components are created and processed in different locations, product quality control procedures play a very important role. Proper identification of the place where the detail was damaged allows to minimise the risk of further errors and proper evaluation of specific units of the company. Many examples of how it is better to double check a product than to make a mistake can be found in the automotive industry.

Automotive companies usually have many factories on different continents, which globally translates into large savings in production, but also involves the effort associated with the appropriate protection of parts during transport. As practice shows, unfortunately, even a well-prepared shipment cannot completely avoid damage to individual products. This problem was the basis of the order we received – to create a machine with a module for verifying the condition of components, gear shift levers.

So far, our principal has only been tasked with arming the lever after receiving delivery from Asia. However, there have been times when the box failed to perform its function after all the work has been done. There could be many reasons, but it was difficult to verify where the component was damaged – in transit or during arming.

Process flow

The manufacturer in Asia takes appropriate steps to prevent the shipment of faulty components by subjecting them to verification at the factory in Asia before the shipment. If they meet all standards, they qualify for further processing and are sent to Poland. Once they have been brought to their final destination, the levers go into a machine we have constructed with an inspection module and assembly stations.

There, instead of immediate arming – as was the case until now – the transmission lever is first parameterised, checked for damage, mechanical efficiency and compliance. It is then armed, fitted with the appropriate components and given a label. The final step is to install the bellows with the shift knob fitted to the shifter.

Solution to the problem

The element that proved to be crucial in building this machine is the IO-Link system. It allowed us to reduce the number of wires. It also gave the ability to connect distributed modules, reduced the need for adjustments and made diagnostics easier. We also used printers, barcode scanners and a vision system. The latter is very widely used due to the large number of elements to be detected. It allows the presence of all screws or small components to be verified, which are so difficult to access that optical or inductive sensors prove to be insufficient. The vision system also allows you to check that the workpiece is in the correct position, that there has been no misalignment in the process between the tester and the assembly station, and that all parts are as specified. It is also used to check quality at the end of the process.

Use of Balluff tools

Most of the tools used are Balluff solutions. In addition to those already mentioned, we also used a handheld barcode scanner and a desktop BVS that can be used to scan QR codes. We applied a distributed system based on a profinet master on IO-Link, components of Balluff’s security system – barriers and security limiters, as well as the entire vision system: BVS cameras and a smart camera.

Thanks to cooperation with Jarosław Burzawa from Balluff, the process of implementation of these tools went very smoothly and the whole project took about six months.

Benefits for the company

With a machine equipped with an inspection system, the company receives fewer complaints. The ability to verify where a mistake was made makes it easier to identify the entity responsible for meeting the terms agreed with the customer. It also allows you to find the right procedures for transporting the parts, if it turns out that it is during the journey that they are most often damaged.

The machine we built is easier to service, and it also has the advantage that while it still requires two to three people to operate it, their work is now much smoother.

Use in other areas

The device prepared by us is a universal solution that can be used in many companies. Its specificity depends only on the type of detail or raw material that is to be verified and processed.

R.J. Company. Automatyka s.c. is a leading supplier of production lines and a specialist in the implementation of industrial automation systems. Our team consists of a group of professionals with experience in designing, building, execution, and commissioning of control systems in industrial facilities. We have gained our knowledge and competence while implementing projects for a wide range of clients.