Maximizing Error-proofing in Manufacturing with MES/MOM Controlled Assembly Tools

This document summarizes the error-proofing solution a leading heavy machinery manufacturer implemented and standardized on in order to greatly reduce product defects due to improperly fastened bolts in transmission systems. Electric assembly tools called nutrunners are used by assembly line workers to fasten bolts to a predetermined torque measurement. Their decision to implement a manufacturing execution system (MES) or manufacturing operations management (MOM) software to both ‘monitor’ and ‘control’ all aspects of the assembly tools and line worker processes yielded unprecedented results by reducing bolted joint failures and Warranty claims by 94%.

The solution was to integrate a manufacturing execution system in order to error-proof all processes on the assembly line, be it by tool or device, or human. Further, the system contributed to a paradigm shift in that a culture of ‘full-accountability’ was born into the customer’s manufacturing operations. PINpoint MES/MOM provided the customer a web based ‘configurable’ plant floor management system with the added-value of integral manufacturing optimization features. The MES/MOM filled the void between the customer’s Enterprise Resource Planning (ERP) system and the processes on the assembly line themselves. With the capabilities to both ‘monitor’ and ‘control’ the assembly line processes the MES/MOM ensured no one bit of information or action was unaccounted for. In-turn the process history recorded served to allow for the query of data and output of valuable manufacturing reports which were used to further optimize their manufacturing processes. Concerning their specific physical problem of bolted joint failures the MES/MOM provided full-control over the electric tool itself, with the capability to ‘lock’ the tool should an installation parameter not be met. Locking out the nutrunners eliminated any chance of the line worker from attempting to pass the defective part.

• [Efficiency Improvement - Quality Assurance]
  Manufacturing Execution System (MES) software both ‘monitored’ and ‘controlled’ all aspects of the assembly tools and line worker processes; yielding unprecedented results by reducing bolted joint failures and Warranty claims by 94%.

• 94% reduction in bolted joint failures, and Warranty claims.