Mobile Data Collection - Manufacturing - Error Proofing Smart Systems

Overview of ADR's Error Proofing Smart System (EPSS)

ADR has recognized the critical importance of error proofing in the automotive industry. We have been improving our EPSS over the last 9 years and believe it to be the best cost effective error proofing solution available today. It was designed to be reliable, yet robust and flexible, a hard combination to accomplish. Recent improvements over the last few years include adding final part number traceability, network card IP addressing capability (SAP communication) and incorporating the second party verification (QCS) right into our EPSS system. We have always had the automated move order capability, the parking ticket capability and the print on demand capability.

We understand the best error proofing practices to include the following: automated move order capability, print part labels on demand (no batch printing), parking ticket capability, second party verification and part traceability (EPSS offers final part traceability). ADR will continue to explore new ways to improve error proofing and has designed our EPSS to be flexible enough to allow us to do so. Our WDPRO application with its Smart Script interpreted software language allows us to quickly custom program each assembly lines error proofing requirements on the fly without recompiling.

EPSS is made up of three modules, Automated Move Order System (AMOS), Watch Dog Pro (WDPRO) that includes Smart Script interpreted language and MainFrame Smart Link (MFSL). These modules work together seamlessly to ensure that the error proofing processes defined for a particular cell or assembly line are thoroughly followed.

AMOS is the database where all part information is set up. For easy part set up, a minimum of only seven pieces of information is required for the system to fully interface with the AS/400 to generate a move order. The AMOS database has capabilities to allow for the cross-referencing of part data, the storage of data related to scales (i.e. average part weight, tolerances, bin weight, dunnage weight, etc.), and multiple barcode label formats.

WDPRO utilizes all of AMOS's part data to ensure that a cells error proofing process is fully followed. Watch Dog Pro is a development environment similar to Visual Basic or Delphi that allows for very fast programming changes on the fly. To add another device such as a scanner or a printer requires nothing more then placing the respective component on the form and adding a few lines of code. The system requires absolutely NO re-compilation of source code. Prompts and verification notices can be added to the screen as desired. All access is password protected. On a typical system, the administrator is given a folder with build templates or process picture sheets of each part run in that cell along with its barcode. After logging on to the AS/400, the user scans the build template to set up the desired part. At that point, the system will check to see if there are any partial bins existing for that part. If there is a partial, the user is warned and is forced to scan the correct "EPSS generated partial bin barcode" to set the part up. Once the correct barcode is scanned, the label format is sent to the part label printer and the system is set up and ready to go. As parts travel down the line and the label is scanned and error proofed, all required information is logged and a counter on the PC is incremented. If an incorrect part is introduced, the user is notified and corrective action must be taken. When the standard pack of a part is reached, all move order data is sent to the AS/400 and a move order label is sent to the printer.

MFSL is the third and final module of EPSS. This module is solely responsible for the connectivity to any AS/400 mainframe computer. Mainframe Smart Link employs the same scripting language used by Watch Dog Pro. Through Object Linking and Embedding and Dynamic Data Exchange, the modules are able to communicate with one another and Mainframe Smart Link is able to communicate directly with Attachmate's software, which is linked to the mainframe.

Some of the best error proofing practices, all of which ADR's EPSS includes, are summarized below:

Automated Move Order Capability.
EPSS error proofs and counts each correct part packed into the shipping container. When the standard pack is reached, it is programmed to and does automatically process the move order. It also has an option that prompts and requests the operator scan a part in the shipping container before the move order will be processed offering additional error proofing.
Print Part Labels on Demand (no batch printing)
There are two ways to set up a printer to print on demand. The first involves automatically setting the printer up when the system is set up. This style set up is easier on the administrator because everything is taken care of behind the scenes. The set up occurs when the build template is scanned and labels are made readily available, as they are needed. The second way involves having the administrator manually select the part to be run, even after setting up the system via scanning the build template. This style set up further error proofs the system because the user is less likely to set up the wrong part twice.
Parking Ticket Capability
Parking ticket capability allows for partial bins to be set aside with a specific EPSS generated partial bin label with a barcode, until the requirement for that part returns. All data associated with a particular bin is logged in the system until a need for it comes forth. If a user tries to set up a part that is logged as partial, the system will NOT allow the part to be run until the correct partial barcode is scanned. When it is scanned, the data is introduced back into the system and it is left like it was before it was a partial.
Second Party Verification
Second party verification verifies the correct move order (shipping label) is placed onto the correct container of parts. This, along with EPSS's other error proofing solutions assures the correct parts and quantity of parts gets shipped to the correct location. Quality Check System (QCS) is now fully integrated with EPSS allowing for easy "OK to Ship" label generation. It makes sure the current part set up and running matches the part number of a part in the full shipping container and the part number on the move order (shipping label) that is already attached to the shipping container. Then the serial number of the move order is also scanned to verify unique move order. The initials of the verifier, the date & time, the serial number of the move order and an "OK to Ship" message are all printed onto a label that is attached to the shipping container, near the move order (shipping label), signifying "OK to Ship". QCS is fully customizable giving the user as many scans/configurations required to ensure that the correct move order is place on the bin.
Part Traceability
Part Traceability records each parts unique serial number along with a date and time stamp and matches those parts to the serial number of the move order (shipping label) of the bin they were placed in. In EPSS, after a move order is generated, the user is prompted to scan the serial number on it to tie it to the part data. All data is logged in a file and is accessible by date. Each serial number is verified as unique.

In conclusion, EPSS offers the most cost effective, reliable, flexible, PROVEN quality error proofing solution available today! To ensure your company's shipping quality is Six Sigma compliant, utilize ADR's EPSS to eliminate product, process and label errors. EPSS will ensure the correct parts and quantity of parts get shipped to the correct location and that there are no mis-labeled or mixed labeled parts or containers.

Detailed Summary of ADR Error Proofing Smart System (EPSS)

EPSS provides the following error proofing solutions. Summarized, they assure the correct parts get the correct label and the correct parts and quantity of parts get shipped to the correct location.

Verifying the correct part gets the correct part label attached. Accomplished with the run setup function of EPSS that utilizes the build template, or process picture sheet with bar code label of the part to be run, to set up the current part. After the operator logs onto the mainframe via a logon ID and password, and the supervisor provides the build template, they then scan run setup and set up the part to be run. At the same time the printer gets set up to print the correct labels. Serialized barcode label generation can also be accomplished with EPSS.
Verifying the part label is present and legible. Accomplished with Scanning since the action of scanning for verification purposes, by default, verifies presence and won't scan if not legible.
Verifying the part is verified to be the correct part before packing. Accomplished with Scanning by comparing the part scanned to the part the EPSS was set up to run. If it is the same, then you have verified it is the correct part number and also verified runtime. Changeover procedures address changeover situations.
Verifying the correct quantity of parts is packed. Accomplished with Scanning that counts each unit whose part number (or serialized barcode) was verified to be correct. This info is displayed on the screen. EPSS error proofs and counts each correct part packed into the shipping container. When the standard pack is reached, it is programmed to and does automatically process the move order. It also has an option that prompts and requests the operator scan a part in the shipping container before the move order will be processed offering additional error proofing.
Verifying the part label part number matches the shipping label part number. Accomplished with the QCS function of EPSS. Second party verification verifies the correct move order (shipping label) is placed onto the correct container of parts. This, along with EPSS's other error proofing solutions, assures the correct parts and quantity of parts gets shipped to the correct location. Quality Check System (QCS) is now fully integrated with EPSS allowing for easy "OK to Ship" label generation. It makes sure the current part set up and running matches the part number of a part in the full shipping container and the part number on the move order (shipping label) that is already attached to the shipping container. Then the serial number of the move order is also scanned to verify unique move order. The initials of the verifier, the date & time, the serial number of the move order and an "OK to Ship" message are all printed onto a label that is attached to the shipping container, near the move order (shipping label), signifying "OK to Ship". QCS is fully customizable giving the user as many scans/configurations required to ensure that the correct move order is place on the bin.
Verifying and reintroducing the partial packs back into production. Accomplished with the partial pack feature of EPSS. Parking ticket capability allows for partial bins to be set aside with a specific EPSS generated partial bin label with a barcode, until the requirement for that part returns. All data associated with a particular bin is logged in the system until a need for it comes forth. If a user tries to set up a part that is logged as partial, the EPSS will NOT allow the part to be run until the correct partial barcode is scanned. When it is scanned, the data is introduced back into the system and it is displayed like it was before it was a partial. EPSS could also communicate partial data to the network if required.

ADR's EPSS (Error Proofing Smart System) can accomplish all of the above and more by utilizing the 3 main applications (AMOS, MFSL & WDPRO) along with the Smart Script interpreted programming language ADR developed in house. ADR has strived to be the best in error proofing and has recently implemented changes allowing us to offer a near Class "A" error proofing system. The summary of options EPSS offers is described below.

The Standard EPSS includes Automated Move Order capability (AMOS & MFSL), Print on Demand capability (WDPRO), Parking Ticket capability (WDPRO), Second Party Verification capability (QCS) and Final Part Traceability. The most effective bar code verification method is accomplished utilizing a scanner. Count can also be verified via a scale option or PLC option but scanning is the recommended option. Count via PLC sending the part and/or serial number data to our EPSS, which is then error proofed. Count via Scanning can be accomplished a few ways with either fixed or portable scanners. One way is to scan every part after final dock audit before packing. Another way is to scan every part after packing by scanning each layer of parts. Count via Scale option. This can be done a few ways as well. Weigh each individual part as it is added to the shipping container by defining average piece part weight and tolerances, dunnage weight, etc. Another way is to weigh the total (gross) and divide by the average piece part weight and layer dunnage.

Final Part Traceability records each parts unique serial number along with a date and time stamp and matches those parts to the serial number of the move order (shipping label) of the bin they were placed in. In EPSS, after a move order is generated, the user is prompted to scan the serial number on it to tie it to the part data. All data is logged in a file and is accessible by date. Each serial number is verified as unique. Piece part traceability, along with final part traceability, will some day be a requirement in the automotive industry. ADR has designed a solution to accommodate multiple inputs from scanners, PLC's, etc to be able record & save all piece part data, which is tied to the final part number, which is tied to the shipping label for total traceability.

EPSS is also open, modular, industry standard, flexible, user friendly, scaleable and upgradeable.

Open - EPSS utilizes the latest hardware and software technologies available. It uses commercial or industrial PC's and Windows operating systems that can accommodate and support common industry interfaces. These features, along with WDPRO's Smart Script interpreted language, used to quickly custom program error proofing requirements right on the line without having to recompile, allow EPSS to easily integrate any type of hardware. All access is password protected.
Modular - EPSS does consist of 3 modules, AMOS, WDPRO and MFSL. Each has their own function and also communicates with each other. The Smart Script interpreted language is used to communicate between each of these modules through Object Linking, Embedding and Dynamic Data Exchange.
Industry Standards - EPSS again uses the latest technologies in commercial or industrial PC's and Windows operating systems that can accommodate and support common industry interfaces. Through MFSL and Attachmate software EPSS can communicate via coax, TCPIP and all other network communication protocols.
Flexible - As stated above, EPSS uses WDPRO's Smart Script interpreted language to quickly custom program error proofing requirements right on the line without having to recompile, allow EPSS to easily integrate any type of hardware. All access is password protected.
User Friendly - EPSS displays all relevant data, in a user-friendly fashion, requiring no manual entry other than logon ID and password. It displays error messages along with prompts on how to easily recover from the errors. It has a current "status of process" banner that always monitors status and prompts for next process required. The AMOS database setup has a user friendly, windows program like GUI that can be easily navigated and each parts data can be entered in less than 1 minute. Utilizing the run setup barcode and set up scanner, you can set up a part to be run in a matter of seconds, once you are logged on.
Scaleable - ADR understands that all lines are not created equal. Each assembly line can and does seem to have its own unique requirements resulting in minor tweaking of software. But thanks to WDPRO's Smart Script interpreted language, these are easily handled. Future error proofing requirements will be easily accommodated through the modularity and flexibility of EPSS.
Upgradeable - As stated in other points above, EPSS can adapt to most any hardware platform and interface, communicate to any network infrastructure and accommodate any future error proofing solutions. Working with the latest Windows operating system and software development packages, EPSS can expand its capabilities to meet the needs of each assembly line. Whether it's an ACCESS or ORACLE database, COAX or TCPIP network communication protocol, or any custom third party software package (SAP ERP system), EPSS is ready for the challenge.

Benefits

Development software - Utilizes the latest software development packages available.
Customization software - Additional and unique error proofing needs can always be accommodated with EPSS and WDPRO's Smart Script interpreted language. Whether it's a particulars plant internal process difference (i.e. shipping label or manufacturing pack label), EPSS can easily adapt. Interfacing with external devices and communicating with networks and delivering an error proofing solution is what EPSS does best.
Service and Support - No annual service fee! With proper hardware and process maintenance, EPSS requires minimal service and support. Plants with over 1 dozen EPSS's each have gone over 1 year without requiring a service call related to an issue with EPSS. Most service calls are related to adding additional error proofing methods. All service is time and material and thru ADR's networked organization, nationwide service and support will be available.
2D Labels - 2D labeling is already in process in the automotive industry. EPSS has been designed to accommodate any requirements in this area. Successful testing has been performed with 2D bar code scanners and 2d label error proofing requirements.
SAP ERP Ready - Following the definition of SAP communication protocol requirements, EPSS will communicate the appropriate data to the selected recipient. Network card with IP addressing has been successfully tested and is ready for implementation.
Assembly line controllers - EPSS currently has the capability to communicate with assembly line controllers. We either control or have controlled items like stack alarms, that display pass or fail lights and alarms, and other assembly line functions. Also currently receiving data from the controller that includes the part number and serial number that is error proofed and recorded for traceability.
Process improvements - ADR has gained extensive knowledge over the last 7 years with error proofing solutions, especially with Delphi assembly processes. Future process improvements to consider should include final part traceability, piece part traceability, 2 D bar code labels, printer label verifiers, label applicators and production run reporting.