All companies must be prepared for the return of products for whatever reason. And a production plant is no different. Both the number and the reasons for returns or defects detected in production must be controlled if your company wishes to improve its reject ratio.
Article by Jesús Martínez, Director of Global Project Office
This does not apply only to the more evident causes (physical defects, defects caused by the machine, incorrect part parameters, inadequate handling, etc.) but also to the ultimate cause of the problem (raw material from a particular supplier, specific machine or individual operator).
Among other data, these reviews can specify the quality of the parts to decide in real time which parts are valid and which must be rejected. The invalid parts will be those lost in production or scrapped, which means that the entire process must be repeated to create the part again.
Knowing the reasons why a part is unusable and must be manufactured again is of vital importance to the company. Reworking may be caused by a machine that destroys the parts and requires corrective maintenance or to defective raw material.
Lantek has developed several applications to review the validation of manufactured pieces:
• Work validator centralized in Lantek Manager and Lantek Integra
• Lantek Wos at the operator’s workstation
• Lantek Workshop Capture for high mobility situations
Control must be enabled and a reason assigned for the defects in every rejected part in order to ascertain the cause of the lost production. With these systems - customized to adapt to the real production plant scenario - Lantek provides the option of recording the reasons for lost production.
The company can use these data to perform periodic studies of the rejected parts and thus work towards reducing the number of unusable parts to foster continuous improvement. Lantek provides a log that enables creation of different types of report to perform these studies. You will be able to see the reasons why parts are scrapped in a particular work center, how many parts are scrapped by a specific operator and how many parts have been lost within a certain timeframe.
In short, Lantek provides the support required to make the application of continuous improvement and total quality policies simple and easy to implement and fully integrate into the operators’ normal work routines, ensuring that the data is entered in a systematic manner. The system guarantees that the data is fully valid and therefore the conclusions reached are based on the real parameters of your production sequence.
In the same way that the heart pumps blood in different ways according to the requirements of the body, the MES gives the production manager the ability to adapt to the pace and characteristics of the company, its customers and its production plants.
The Spanish industrial sector is facing an enormous challenge in order to become more competitive in the midst of digital transformation and in a market in which new consumer habits are pushing us towards a new form of manufacturing. The client in the digital era wants THEIR order (in capital letters because they don’t want what’s standard, they want something that’s customized) and they want it in record time, which requires us to be more streamlined and fast.