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Electronic and electrical connector
manufactures and contract manufactures must use exacting materials and
assembly methods in order to prevent defects and their subsequent
hazards to property and people. Meeting UL, CSA, VDE and other agency
regulations is essential. Increasingly, manufactures are implementing
software-driven statistical process control (SPC) techniques. As a
result, millions of dollars that would be otherwise be wasted as scrap,
rework and customer returns are being saved.
At a Canadian electrical and electronic terminal block and connector
manufacturing facility, a sales increase of $200,000 on a $1,000,000
account took place as a result of the facility’s improved SPC methods.
Having tolerated laborious computations by hand for years, this
multinational company now uses SPC software to serve its needs.
Bottom-line cost improvements are mirroring the use of the SPC software,
and the software’s return on investment was swift -- just four months.
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About the
Company
WECO Electrical Connectors Inc. produces terminal blocks and connectors
for printed circuit, panel/chassis and rail-mounted applications.
Although the United States is its biggest market, the company has a
world- wide customer base with manufacturing facilities in Germany,
Canada, Switzerland and Tunisia. Its terminal blocks and connectors are
supplied to industries such as heating ventilation and air conditioning
(HVAC), industrial controls, and instrumentation and telecom equipment,
among others.
Choosing the Software
In October 1998, after years of using personal computer (PC)
spreadsheets and graphs to monitor production quality, WECO began using
an SPC software package named Synergy Enterprise Quality Management (EQM)
from Zontec Inc. (Cincinnati). Before purchasing it, WECO researched SPC
software vendors to get comprehensive knowledge of the software features
that were available.
WECO’S need for SPC software was essential. The target was to invest in
improved manufacturing processes to enhance capabilities and increase
quality rating. Zontec’s SPC software allowed WECO to increase control
and slash defects.
How It Works
The three-tier SPC software package features operator, engineer, and
manager-level programs. At the operator’s tier, measurement data
automatically enters the Synergy software via a Mitutoyo gauge setup.
Operators view the production status via green- yellow- red status flags
or control charts, or both simultaneously. Green status flags indicate
within spec; yellow means potential nonspec; and red is out of spec.
Other details that appear include identification numbers and corrective
actions. A query function allows operators to extract data by lot
number, operator identification, time/date or certain combinations of
critical identifiers. The result is instantaneous analysis, enabling
operators to take the appropriate corrective action. Typical operator
corrective actions usually focus on machine adjustments.
The software’s second tier permits engineers and technicians to create,
modify and customize job setups. The third tier, the plant manager’s
level, acts as a "command center" of sorts. Mouse clicks at this level
show how in or out of control each process is at every workstation on
the network. This tier also generates enterprise-wide summary reports.
Installation
The installation requirements for the SPC software were clear – easy
integration. WECO wanted to avoid finger pointing among its information
systems personnel, the software manufacturer and the data acquisition
hardware manufacturer. To prepare for a smooth transition, WECO
installed a server, new computers, LAN lines, multiplexers and measuring
instruments during a 10-day period. Zontec provided training, support,
software and multiplexers.
Manufacturing Today
The SPC software is installed in six computers on the production line to
monitor connection dimensions and machinery performance. Mitutoyo gauges
attach to the computers to take automatic readings from the manufactured
parts, resulting in hefty timesavings over manual entry. Production
machines are evaluated in real time, being stopped and adjusted when
necessary. The result is fewer defects and better machine output
diagnostics.
Several diagnostic tools are in use on the production floor, including
X-Bar & R, attribute, Pareto, and gauge repeatability and
reproducibility (R & R) charts. Capability and performance indices of
Cpk, Cp, Ppk and Pp can be accessed during and after production. Cp and
Pp show how capable the process is in making parts that are within
engineering specs. Cpk and Ppk are measures of how centered the process
distribution is when compared with specification limits. Real-time
monitoring and subsequent adjustments are now getting substantially more
products through final inspection.
Before WECO began using SPC software, nonconforming parts were causing
rework, repair and scrap, in addition to lost time and missed delivery
windows, but no more. Heiner Kammann, president of WECO, sums up the SPC
before and after picture: "Not purchasing the [SPC software] would
inevitably lead to a loss of clients and higher expenses. With the
software, we can control the process and avoid lack of quality in
components." |
