This enables you to consider the problem from the perspective of the part instead of just looking at the station for more effective, actionable insights. With the right sensors and software, existing process stations on the line can be equipped with the intelligence tools to collect, correlate and visualize the highly granular part production data that is generated by the part, not the machine, during a process or test cycle. A flaw with any one, or more, of these processes could be responsible for that leak test fail. At previous stations, this part has been drilled and clamped, and was subject to a dispensing operation and a weld. Take, for example, a part that has failed a leak test. Simple-find out why, by collecting and analyzing the right data. With the above points in mind, the next logical question is what do when a defect is detected, or a part fails a quality check. Gain real value from your part production data Learn more about why relying on end-of-line testing is bad for your bottom line > 3. Instead, consider what checks and balances can, and should, be instituted at every critical juncture as a part or assembly progresses down the line. But again, for overall quality gains, your team’s focus must be on more than just a final quality check. That’s not to say that end-of-line or other downstream testing don’t have their place. Why continue to put time, money and materials into a part or sub-assembly that may have to be scrapped? The closer to its point of origin that you detect and define a production flaw that is impacting FTY, the less disruptive it will be to overall production, and the less costly it will be to fix.Īnd yet, many lines continue to rely on test, inspection and quality control methods that push defect detection downstream. Detect defects where, and when, they start Here is a deeper dive into first time yield, where we offer a case study example of how a line saved more than $3 million a year by increasing FTY from 90 to 98% > 2. The result is a scrap or rework rate of 40%. That 99% may sound high, but by the end of the line, the Rolling Throughput Yield, or RTY, is only about 60%. The more stations there are on a line, the greater the need for a data-driven quality assurance process that can ensure the FTY at each station is as close as possible to 100%.įor example, consider a line that has 50 stations in series and each station operating, on average, with an FTY of 99%. Start with a hard look at First Time Yield (FTY) We continue to see the greatest value in making the most of what you already have.īelow, we share 5 tips to consider as you work to improve your production line efficiency, and product quality. On the production line, it’s all about reaching higher levels of product quality and efficiency.īut this doesn’t mean you have to engage in a costly rip-and-replace of legacy equipment. Manufacturers across all industries are being challenged to reconsider what they do and how they do it.
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