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What can AQIs do

AQIs supports you in the following tasks and processes:

Test dynamically and efficiently

AQIs test stand of IGH Automation

With the aid of an AQIs test stand, you can test the quality and functionality of a subassembly or end product at a test stand, perform parameterisations, teach properties and acquire data that requires documentation.

 

For testing unfinished products, AQIs provides simulation of the rest of the system, so that all test are carried out as though the product already contained all functioning components. This guarantees assembly of fault-free components.

 

The test stand has sensors and bus communication. The measuring technology of the test stand is tailored to the measuring task on a customer-specific basis, the AQIs software is universal and is parameterised by the user for the actual measuring task.

 

Mobile tests are also possible via a WLAN interface between the UUT, measuring system and test stand.

 

UUT faults detected during the test are saved in the AQIs database on the AQIs server. Following a repair to the UUT, the error is eliminated in a follow-up test but remains in the database for statistical evaluations.

Defining individual checklists

Operator digitally processing AQIs checklists

With the Intranet solution AQIs Checklists, you can edit checklists digitally. Checklists for a work station contain testing and documentation tasks of functions and qualitative characteristics. They can be used:

 

  • for the incoming goods inspection
  • in preassembly and assembly for monitoring the progress of work and the quality of the subassembly, e.g. as an operator self-test or at a quality gate
  • for the final inspection, commissioning and functional test of the finished product
  • as a pre-delivery inspection immediately before delivery

 

The check points in a checklist are parameterised and allow not only testing for qualitative characteristics (yes/no, OK/not OK, good/bad, done/not done) but are also used for documentation, e.g. for recording serial and batch numbers that must be documented, set parameters and product properties attained.

 

The check points in a checklist can be run through in sequence or in any desired order.

 

Check points answered in the negative are saved as errors in the AQIs database on the AQIs server. After the problem has been remedied, the error is eliminated again but remains in the database for statistical evaluations.

Detecting and tracking errors systematically

Systematic error detection in production and assembly

The AQIs Fault Management is an Intranet solution for digitally detecting UUT errors independently of one work station. This enables errors that are detected on the UUT during the production process to be documented digitally at any time, independently of questions in checklists or measurements at test stands. These errors are saved in the AQIs database on the AQIs server.

 

All other errors from checklists and measuring tests that are detected by AQIs are also tracked here.

 

After the problem has been remedied, the error is eliminated again but remains in the database for statistical evaluations.

 

The AQIs Fault Management module gives you an overview of the error situation on every UTT.

Precision control of reworking

Rework control directly on the PC

The module AQIs Rework Control is for managing all faulty units under test. This gives you an overview of all open errors, regardless of whether they have been entered at a measuring test station, via AQIs checklists or in the AQIs Fault Management module.

 

In AQIs Rework Control, you manage the latest manufacturing data, the locations of the faults products and plan rework and repairs for every error and for every operator.

 

Priority lists can be kept for resources, e.g. painting. AQIs Rework Control also supports the retrofitting of missing parts.

 

After a fault has been repaired, the error is removed again and the AQIs rework can be documented. However, the removed error remains in the database for the purpose of statistical evaluations.

Complete and paper-free documentation

AQIs Test Report

Our customers have different requirements in terms of the documentation of their production and products.

 

Documentation tasks arise from your requirements, legal stipulations, product liability and also the conditions of associations and professional liability insurance bodies.

 

Relevant AQIs modules supply data for systematic digital documentation, whereby the actual amount of documentation can be parameterised by you.

 

This documentation gives you:

 

Traceability: Who did what with your product in AQIs - and when - are documented. For example, who carried out a measuring test, with which parameters, with which setpoint values, with what success, with what result a checklist was worked through, which errors were detected and removed again.

 

Compiling a digital product file during a measuring test or while running through a checklist, it is possible to record serial and batch numbers of subassemblies that require documentation (known as machine card data). Measured values, data from CAN bus telegrams and all test tasks carried out are saved in AQIs.

 

Also, all set parameters and teach values from the controllers can be documented in AQIs. [more]

 

Service support: From knowledge of the data relating to how a product has been manufactured, tested and parameterised, Service can carry out repairs and replace subassemblies at low cost, and fend off warranty claims.

 

Evidence of product liability: From knowledge of the data relating to how a product has been manufactured, tested and parameterised, you can provide evidence of your care and either reduce or fend off liability claims.

 

Recall support: In the event of series faults in a subassembly, e.g. due to a supplier's manufacturing fault, you can organise an appropriate recall both quickly and at low cost because you can find out without any problem which end products are affected by the fault.

 

Reproducibility of the product tests: You parameterise all test tasks together with their sequence, setpoint values and tolerances, as well as all checklist points, and you release them for use in production. This enables you to always see which UUT has been checked, put into operation and parameterised with which specifications. All tasks are reproducible independently. The testing scope and the test results are not dependent on individual capabilities and skills of the tester.

 

All documentation data is saved in the AQIs database on the AQIs server and can be interrogated and evaluated via the AQIs report.

 

In addition, AQIs can automatically make any desired data available to other IT systems in your company for their tasks, as though the data had been acquired there.

Motivating staff through visualisation in production

The AQIs andon board module visualises important key performance indicators (KPI, e.g. OEE) in production

With the AQIs module Andon Board, you can visualise important key performance indicators (KPI, e.g. OEE) in your production. You provide your staff with information on the current production status, quantities, error statuses, cycle times etc. Large monitors (40“ to 60“) are used as andon boards, located in easily visible positions in the assembly hall.

 

The contents to be shown are generated from data in the AQIs database and other IT systems networked in your company.

 

In break times for example, it is possible for directors or the Works Council to show self-running Powerpoint presentations on current events, topics and projects.

Depicting assembly tasks in an understandable way

AQIs operator guidance depicts assembly tasks for the operators on work sheets.

The AQIs Operator Guidance depicts assembly tasks in relation to work stations and customer orders in both pre-assembly and on the assembly line.

 

For this, IT terminal devices such as panel PCs are installed at each work station. After a job is registered on the work station PC, all work tasks for this job are displayed as worksheets on this station in the specified technical sequence.

 

Important contents in the depiction of a job in a worksheet are:

 

  • Graphic representations / photos / design plans for this job
  • Parts list of individual parts and subassemblies with information on tools
  • Description of the job in text form
  • Links to other documents with detailed information
  • Sorting criteria of the worksheet, e.g. line, station, number in the work sequence etc.

 

Part of the operator guidance is a planning tool with which your technical planning department can compile or manage the production parts list based on the design parts list. In the planning tool the assembly tasks are structured, broken down into small units and assigned to work stations. Every assembly task is described and illustrated with graphics.

 

When the production parts list is managed in AQIs, the data can be returned to your ERP system or to other IT systems so as to manage your material supply with the delivery addresses.

Inform, report and evaluate

Test reports, statistics and reports are compiled with AQIs.

Test reports

With AQIs, after every test it is possible to compile test reports in a layout and with contents defined by you as a PDF file, and make them available to a document management system or other IT systems or print them out.

 

These test reports are also suitable as data sheets for archiving or for passing on to your customers, as documentation of assured properties, as certificates or acceptance logs for authorities and approval bodies.

 

Statistics

All data for AQIs is saved in the AQIs database on the AQIs server. Specifically, these are:

 

  • The company-wide error code
  • All test stations and types of unit under test
  • All test plans and setpoint values with tolerances
  • All tests performed, with the tester and testing effort, serial number of the unit under test
  • Master data, serial numbers of subassemblies, configurations of all units under test
  • Detected and remedied errors
  • Measured values, parameters and teach results
  • All results of working through the checklist

 

Report

The global aim of using AQIs is production optimisation. After data acquisition, essential elements of this are visualisation, statistics and evaluation of the data. Possible tasks for the AQIs report are:

 

  • Evaluation of the error situation per station / line / type of unit under test (series) / time period with regard to frequency and rework effort
  • Evaluation of the test times per station / line / type of unit under test (series) / time period
  • Evaluation of the measured values, parameters and teach results
  • Documentation, research, traceability

 

With this information, you know where the most significant and most frequent faults can occur, enabling you to optimise your production efficiently. After the user has selected the parameters, AQIs Report creates files with the reports in Excel format or as a PDF file. These files can be further processed as desired (saved, copied, printed, mailed etc.).

Compile complete product files digitally

AQIs keeps digital product files.

Every unit under test is identified in AQIs by a unique number, this being the ID number that is also used in your systems to identify the product.

 

All data relating to the UUT is saved under its ID number in the AQIs database. With this, AQIs keeps a digital product file.

 

The more AQIs work stations are used in your company, the more tests and data acquisitions that are performed, the more checklists are provided and the more existing stand-alone solutions and QA data of suppliers are integrated, the more complete the digital product file will be. You get increasingly complete and meaningful data about the production process and the properties of your products.

 

Tests and data acquisitions of subassemblies can be done under other number groups or ID number types. When a subassembly is installed into a higher-order subassembly or into the end product, the data in the AQIs database is linked via the ID number of the installed subassembly. As a result, the digital product file of the end product also gets all data from preceding tests and data acquisitions of every subassembly.

 

Selected data or all data of the digital product file in AQIs can be automatically made available in digital form to your ERP system or other IT systems, thereby strengthening your respective leading systems with respect to its data and information requirement.

Communicate with ERP

AQIs can communicate with ERP systems.

AQIs has numerous interfaces for exchanging data with ERP systems or other IT systems. The scope of data and the data mapping are agreed on a customer-specific basis in each case.

 

Important data for AQIs are the customer and production orders with the information on the product's series and on all variants and options that this job contains.

 

In AQIs, test tasks and / or checklists are compiled for every possible variant or option. At the time when a test is running, only the test tasks and check points are performed or displayed that match the active unit under test as per the customer order and that are valid. This avoids the need for the accompanying documents to be read multiple times at different work stations and misinterpretation of the customer order.

 

We regard AQIs as a tool for supplementing your IT systems, adding to your own data additional data that has been acquired automatically and digitally, and offering functions that can be performed better with AQIs than in other IT systems. With AQIs solutions, we are able to claim that we do not replace any ERP functions or acquire duplicate data.

 

AQIs is able to return numerous AQIs-acquired data to other IT systems.

Incorporating stand-alone solutions and data from suppliers without loss

Incorporating data of other test stands into the AQIs system.

AQIs has numerous interfaces for accepting data from other manufacturers' test stands and integrating them into the product files in AQIs.

 

This gives you the possibility of having the data acquired in stand-alone solutions and documented actions made available automatically and digitally in AQIs (and therefore also in your IT systems) for documentation purposes and statistical evaluations. There is no need for manual data transfer, and you do not have to forego the further processing of raw data from separate test stands.

 

In AQIs it is also possible to accept quality data from suppliers of function-determining subassemblies and integrate it into the digital product files in AQIs or make it available for your IT systems.

 

When a subassembly is installed into a higher-order subassembly or into the end product, the supplier's data in the AQIs database is linked via the ID number of the installed subassembly. The digital product file of the end product therefore also receives all data that has already been acquired by the supplier in his QA systems.

Classifying errors systematically

Every error is saved in AQIs with a classifying error code.

Every error that is recognised on the unit under test with the AQIs Fault Management by test tasks that perform measurements or the AQIs checklists is saved with a classifying error code in the AQIs database on the AQIs server. The structure of the error code can be parameterised by you. You can record information about the error location, error type, causes and measures or other information that is important to you about every error.

 

Error code parts can be cascaded in a tree structure, e.g. the error location could be expressed in a three-part error code with Main subassembly » Subassembly » Single part.

 

A possible error is coded by you as early as during parameterisation of the test tasks and check points, so that the operator carrying out a test or who is running through a checklist has no coding tasks. When a UUT fault is detected, the error code stored for the test task is automatically saved in the AQIs database.

 

Free text entry of remarks about an error is always possible.

 

The error coding gives you a uniform error description that is independent of any individual. Misinterpretations and queries are minimised.

 

The error code also allows a meaningful statistical evaluation, e.g. based on certain subassemblies, causers or a type of error with regard to quantity and rework effort. Error prevention strategies can be derived on a targeted basis, which in turn results in production optimisation.

© IGH Automation GmbH 2017