[Thailand / zero defective products] A trial monitor is wanted for a revolutionary system! No NG parts produced in the process. Going beyond the common sense of 100% inspection!

30/04/2020

Nobuhiro Oishi

Managing Director

NANO SEIMITSU

(Left) Mr. Oishi, MD of Nano Seimitsu (Right) Mr. Fukusho a who developed software as main person

Even if we try to promote 100% automatic sorting, not all of them can be automated due to the current technical and cost aspects. Differences in inspection accuracy, such as 100 microns and 10 microns, are also a major obstacle to 100% sorting. If you are dealing with a lot of products with an outside diameter tolerance of 10 microns or less, it is not so easy to perform 100% sorting using a camera.

However, it is the fate of parts manufacturers that even one-in-a-million pieces of defective products (NG parts) cannot be outflow.

Then what should we do? How to stop outflow of one-in-a-million pieces of defective products (zero PPM) without 100% automatic inspection?” The answer is "elimination of in-process defects."

However, as that cannot be done, therefore it has been said that “100% automatic sorter is needed”. You might think the story does not make a sense. But maybe there is an "in-process guarantee method" that can guarantee almost close to 100%. Isn't there a method to inspect with sampling, which with more reliable quality control to prevent the occurrence of defective products in advance? Is there a way to create a system that can monitor more mechanically and complete operation according to the rules? It was that timing when I was thinking about these ideas, that I encountered with the president of Office H.F, Hiroo Fukusho

Software to eradicate in-process defects will become the standard for parts manufacturing!?

Mr. Fukusho, who is also an excellent system planner, spoke to me, "Is there anything I can do for you?" Therefore, I discussed the ideas that I was thinking about with in-process monitoring management system, Mr. Fukusho offered full support, saying "This is interesting, let's do it."

After a lot of trial and error, we completed the system called "LINE QC SPECIALIST".

3 features of LINE QC SPECIALIST

① Cannot make abnormal products
② Cannot operate or do work out of the rules
③ If an abnormal product is about to be created, the monitoring software will prompt the machine to stop.

The specific contents are as follows.

・ Measurement instrument calibration management (calibration content, time) = Software intervention in measuring instrument reliability
・ Divide between adjustment and start of mass production = Systemize mass production approval
・ Divide between central control value setting during adjustment and control value setting during mass production = Focus on central control during adjustment
・ Convey the measurement location and measurement frequency to the operators and encourage them to measure the correct location with the correct control value.
・ If "measurement frequency cannot be observed", "measurement value has reached the control value", or "instrument calibration time has been exceeded", the software issues a warning

We are looking for a trial monitor for a new system that will reduce the process management effort!

Usually, in the mass-produced parts, it is rare that a sudden defective product occurs. If it can be managed properly, it can be prevented. However, the patience and physical strength to continue and improve the process control is not easy. Have software take part of it. That is the aim of developing this LINE QC SPECIALSIT. If you are interested in LINE QC SPECIALSIT, please apply for "Trial Monitor" using the inquiry form below.

LINE QC NANO SEIMITSU

▲LINE QC staff visits the assigned manufacturing process facility with a mobile wagon and performs measurements at regular intervals

Measuring instrument that can send measurement data

▲Measuring instrument that can send measurement data

Control chart and trend management display tablet

▲Control chart and trend management display tablet

LINE QC

If you are interested in the LINE QC SPECIALSIT trial monitor, please fill out the form below.

Inquiry Form

Please feel free to contact us from the form as below.

We accept by phone and email.

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