Scrap - Collector and analysis system

Target

Make and print partnumber specific scrap/mistake collector cards, collect all relevant data about the production charges and make more than 35 different scrap/mistake analysis in one system.

Description

1. Basics

All partnumber has got an own scrap/mistake collector card based and used the following basic data:

  • Customer groups
  • customers
  • partnumbers
  • prodution lines
  • workstations
  • raw materials (purchased)
  • raw materials (semifinish parts)
  • mistake/failre types
  • mistake/failure places
  • box label data
  • shift data (shift leader, line manager, date, shift, partnumber, line, workstation and the OK - nOK quantities per workstation)

Important, that the program handels separated the failure types and failure places (e.g. failure type = wrong position | failure place = screw).

2. Scrap collector - injection moulding

Separated data fields for the setup scraps and the serial production scraps. The program prints onto the collector card the quantity of the nOK parts per failure type/place from the last 60 days (dynamic reporting)

On the bottom part of the pages you can drecord the different QM activity which has to be done in case of serial start, shift change of serial end.

3. Scrap collector - assembly

All failure types/places are listed per workstation. On the right side the worker found the lists of the raw materials

Separated data fields for the failures which are detected during the production, in the stations (self control) and for the failures, which are detected at the final control. With this you are able to measure the self control effeciency of the lines.

4. Statistic modul

Actualy the program has got more than 35 different analysis reports. For all reports you have to define different filters, which are marked with coloured squares.

At the reports you see also different coloured squares, which shows, for the needed report which filters has to fullfilled.

Some filter types:

  • Line
  • Workstatios
  • Machines
  • ShifLeaders
  • Linemanagers
  • Partnumbers
  • Failuretypes and mistakes...

5. Daily report

Perfect input for the daily Q-Meeting

  • ppm results per prod. lines
  • Sóscrap costs per prod. groups
  • ppm per shift leaders
  • ppm per PN
  • TOP3 failure analysis (work station - failure type - failure place - nOK in the line - nOK at the final control)

5. Statistic - LLC

  • produced quantity
  • nOK quatity from one failure type/place and ppm of the failure

Maybe the most important stat. modul the LLC reporting. With this report you can easy measure the efficiency of the implemented corrective actions.