Industrial automation software

Sytec Group software controls the workflow of the entire assembly line and of the Quality Gates. It manages the product within the production process, so that it can be identified, checked to see whether it is in a condition that allows testing, and evaluated to determine whether it can move on to the following stages. The testers are placed within a line context, where each test can be carried out only if the product has completed all the upstream processing stages. As the product leaves the line, the product validation function performs a cross-check based on the results of all the tests carried out, determining its fitness for use.

A sequence of fully configurable checks makes it possible to stop production automatically in the event of excessive rejects or dangerous dimensional drift. The aim is to minimize the response time between production and dimensional inspection.

Each step in the assembly chain can be equipped, depending on customer requirements, with simple handling control systems or with interfaces. The interfaces make it possible to enter and/or modify the parameters being measured.

Every component used in the assembly of the finished product can be subject to traceability, whether this is carried out on the basis of the supplier’s production batch or on an individual basis, through a unique code assigned to the component used (Serial Number).

Sytec Group software solutions communicate with the company’s PLC and ERP/MES to achieve full integration between the production and management departments, with the goal of reaching the shared objectives agreed upon in terms of production efficiency, cost control, inventory management, and so on.

Sytec Group software includes a functional testing system whose test sequence is fully configurable and can be associated with each finished product. The test sequence is a combination of physical measurements that are more or less objective depending on the complexity of the measurement. The detected values must fall within a range, or “recipe”, which can be fixed (predetermined) or configurable. Any product that does not pass the required tests must pass through the repair station, where the operator records the operations carried out using a simple interface based on the reading of barcodes defined by quality control.

The system can also include an “Andon” system; the Andon board is one of the main components of the quality control system based on the concept of autonomation. The operator has the option to stop production when a defect is found, in order to request assistance immediately. Common reasons for manually triggering the Andon are component shortages, a defect created or detected, equipment malfunction or the existence of a safety problem. Work is suspended until a solution is found.

The checks on the measuring equipment by means of Golden Samples, requested periodically by the system, are carried out automatically; only passing this test confirms the correct operation of the equipment in production. Thanks to the presence of differentiated user profiles, moreover, the same interface makes it possible to perform the periodic calibration procedures for the measuring rings.

The system is completed by an intuitive machine diagnostics system, as well as a manual handling page for each element of the system for maintenance activities.

The system makes it possible to configure a sequence of steps that simulate the actions of the end customer, specifying the forces involved, the actions to be performed, the sampling frequencies and everything else the system provides. The test bench will stop the test as soon as the conditions are no longer met, or it will continue until all the required actions have been completed. At any time, directly from their own PC, the designated staff can analyze and export the data acquired during the test.

All the measurements collected and the resulting GOOD/FAIL assessments are stored in a relational database and associated with the Serial Number of the individual product.

The system allows access to the data on the company network in order to examine the collected values for statistical purposes or for any “after-the-fact” or “real-time” check of the tests performed. Where the SPC analysis software resides, the data collected on the server is transmitted at predefined intervals to the company’s information systems.