Reducing the amount of diagnosis and reworking
TADANO FAUN GmbH has been a 100% subsidiary of TADANO Ltd. since 1990. The company is the competence centre of the TADANO Group with respect to the development and manufacture of TADANO all-terrain cranes. All TADANO all-terrain cranes are developed and built at the works in Lauf an der Pegnitz near Nuremberg, before being sold all over the world. TADANO FAUN also develops and builds truck-mounted cranes here. These are mounted on ordinary truck chassis. The factory in Bavaria employs over 700 people.
TADANO FAUN GmbH has been a customer of IGH Automation since 2010. When AQIs was introduced, TADANO FAUN opted for staged expansion. The AQIs infrastructure was created in the first stage, and a mobile test system was installed at the assembly end of upper structure production. This is where testing is performed of the upper structure function, and to make sure that there are no faults at the interfaces to the boom and chassis. This ensures that the upper structure is fault-free even before assembly with the boom and chassis.
The next step involved putting two adjustment and test stands into operation in the chassis assembly (lower structure).
Benefit to TADANO FAUN
- Tested subassemblies are delivered for final assembly
- Time saved thanks to automated testing tasks
- Reducing the amount of diagnosis and reworking
- by the staged introduction of manageable investments
Why did you need to re-invest in your testing and measuring systems?
Mr. Henglein: The mobile cranes consist of three main components. These are: Chassis (also known as the lower structure), upper structure and boom. We wanted to test the functions of all three main components before they are assembled together. In the past, part tests of the components were carried out and the completed crane was tested at the end. If the crane was faulty, fault diagnosis was very time-consuming and the crane had to be partially disassembled again in order to be repaired.
Why did you choose the AQIs solution over other solutions?
Mr. Henglein: In AQIs' favour was above all the possibility of extending it in stages and starting off with manageable investments. There was also the fact that when we introduced the first test stand we were able to get acquainted with the system and the software and learn how to use them. We were able to use this for the following test stands, and the software familiarisation phase was eliminated when these were installed.
What did you want to achieve with the investment?
Mr. Henglein: We wanted to shorten the time needed to diagnose and repair a fault, and to digitally record, trace and evaluate the faults later. Our aim was guided test sequences so as to also shorten the production time in that way. Furthermore, we wanted to link the final check of the subassemblies to the measuring system and to digitally document these measurement results. We wanted to construct a digital product file.
Which of your objectives were achieved thanks to the AQIs solution?
Mr. Henglein: We achieved the desired time saving because all adjustment, and test sequences now run automatically in a guided dialog with the tester. The processes are more transparent because a precise analysis of the cause is now possible thanks to the automatically recorded digital test data. We plan on introducing more AQIs test stands.