In an industry where millimeters matter and seconds count, the margin for error in manufacturing assembly is razor-thin. But what if we could navigate that margin and redefine what's possible in production accuracy?
The impacts of incorrectly assembled components extend beyond monetary considerations. They affect production downtime and quality control and ultimately tarnish a company's reputation. RTLS technology emerges as a game-changer, offering innovative solutions to ensure precision in the assembly process and prevent material merging errors.
Through plausibility checks and streamlined process time recording, RTLS not only enhances operational efficiency by providing real-time data but also revolutionizes the manufacturing industry by minimizing errors, optimizing workflow processes, and maximizing productivity.
Dive deeper into RTLS as we explore its transformative capabilities in safeguarding quality, accuracy, and profitability within manufacturing operations.
Prevention of Material Merging Errors through RTLS
Cost factors and effects of incorrectly assembled components/batches
In manufacturing processes, the assembly of components or batches holds a pivotal position in the production chain. Nevertheless, when errors occur during this critical step, they can have substantial cost implications and far-reaching effects on the entire manufacturing process.
Cost factors associated with incorrectly assembled components include rework costs. These costs are incurred when components are assembled incorrectly and must be disassembled, corrected, and reassembled. This results in both direct labor costs and additional material costs if any components are damaged during the disassembly process. Additionally, there are scrap and waste costs involved when components cannot be salvaged or reworked due to damage or extensive errors. These discarded materials contribute to material waste and increase costs.
Production downtime is another significant cost factor stemming from incorrectly assembled components. As issues are identified and addressed, production stoppages occur, directly impacting the bottom line as production schedules are disrupted, and potential customer orders may be delayed. This, in turn, drives up labor costs due to the additional time and effort required for disassembling and reassembling components correctly.
Incorrectly assembled components severely impact a company's bottom line and reputation. They compromise product quality, leading to defects, complaints, and costly recalls that tarnish a company's image. Production disruptions cause delayed deliveries, harming customer relationships and potentially leading to lost sales and penalties. These delays can also create excess inventory, tying up capital, increasing storage costs, and risking obsolete stock. Finally, addressing assembly errors necessitates additional labor and quality control measures, further increasing costs.
How RTLS ensures quality in the assembly process through plausibility checks
Sequencing monitoring
RTLS facilitates automatic (scannerless) plausibility checks of assembly components. This process is executed using RTLS tags installed on assembly carts within the production line. Each tag is associated with specific ID group addresses, indicating the system's responsibility for each assembly area. For example, the assembly carts (frames) for "Product A" have their unique numerical circle for pre-assembly, such as the "engine," as well as for the main assembly line. This approach applies to production line B as well. Consequently, every tag has its own area-specific address, creating a digital network of assembly components capable of tracking manufacturing orders across all assembly branches without the need for paper documentation.
Assembly check with Inpixon’s factory application
The final plausibility check is carried out to determine whether the components can be assembled together. This validation occurs in two geofenced areas, confirming whether each individual component matches the corresponding assembly group before proceeding to the main assembly. The system conducts a systematic comparison within SAP, and a monitor displays whether the components are compatible with each other.
This crucial component check ensures that only compatible components and groups are assembled together. This approach effectively prevents time-consuming and costly rework, thus ensuring the ongoing quality and accuracy of subsequent manufacturing steps. It helps avoid process assembly errors.
The foundation for the plausibility of pre-assembly and main assembly synchronization, sequence-related picking (large components), the generation of transport orders, and sequence-related option displays are all effectively implemented through an RTLS platform.
From Error Prone to Error-Free
As we stand at the brink of a new era in assembly and manufacturing excellence, it is imperative for industry leaders to harness the power of location data and optimize their operational landscapes. This article is just the tiniest tip of the ice berg. To delve deeper into the transformative potential of RTLS in advanced manufacturing and intralogistics, we invite you to download our comprehensive ebook, "The RTLS Playbook for Advanced Manufacturing & Intralogistics." Equip yourself with the tools and insights needed to propel your business toward operational excellence and sustainable growth in the digital age.
Download the ebook here and pave the way toward a future of optimized manufacturing efficiency and unparalleled success.