DE102015204586A1 - Process for manufacturing optimization - Google Patents

Abstract

A method for optimizing manufacturing includes receiving signals that include information about a quality of the manufacturing and determining a match depending on the received signals and at least one predetermined threshold. Furthermore, the method comprises carrying out a respective predetermined action for optimizing the production if no match has been determined as a function of the received signals and the at least one predefined threshold value.

Description

The present invention relates to a method which is suitable for easily optimizing a production.

It is an object to provide a method that is suitable for easily monitoring parameters of a production and, in the event of deviations from predetermined threshold values, initiating measures to optimize the production.

According to a first aspect of the invention, a method of optimizing manufacturing includes receiving signals that include information about a quality of manufacture and determining a match depending on the received signals and at least one predetermined threshold. Furthermore, the method comprises carrying out a respective predetermined action for optimizing the production if no match has been determined as a function of the received signals and the at least one predefined threshold value.

In this way, a method is realized which monitors production in a simple manner and optimizes in dependence on predetermined tolerances. The received signals include, for example, information about a geometry of a product. For example, tolerance ranges are defined by means of predefined threshold values which are intended to adhere to the geometry of the product. For example, by matching the received signals with predetermined threshold values, it can be determined whether a current geometry of a product within a tolerance range coincides with the specifications defined by the threshold values or not.

If a match is determined, the production can continue unchanged without an intervention must be performed. Optionally, it may be displayed visually, for example by means of a green flag on a display, that there are no deviations and that the received signals do not contain information regarding the quality of the production that product parameters are outside a tolerable range.

In the event that no match of the received signals and the associated information with the predetermined thresholds or was determined, a predetermined action is automatically performed, depending on the received signals, for example, a notification of manufacturing personnel, outputting a visual and / or acoustic signal or logging information about the determined deviation.

In this way, it is possible by means of the described method to optimize the production of a production line automated or at least to inform at least responsible manufacturing personnel automatically detected deviations that can promptly take care of a correction and thus to resolve the existing deviation.

According to an embodiment of the first aspect, the execution of a respective predetermined action comprises notifying manufacturing personnel that is assigned to the at least one predefined threshold value and / or the respective predetermined action.

In this way, the associated manufacturing personnel are automatically informed as part of the procedure provided that monitored product characteristics do not match the corresponding predetermined threshold values. This includes, for example, notifying machine personnel who are assigned to supervise a manufacturing machine. For example, a notification may be made electronically by sending an e-mail to a machine operator associated with the identified deviation. Alternatively or additionally, a notification by means of a Messangers or a Piepers or by means of an automated call, for example, on a service phone done to inform the relevant manufacturing personnel that the monitored production is not optimally aligned.

In accordance with a further embodiment of the first aspect, the execution of a respectively prescribed action comprises storing information data in a first memory which contains information about the respectively executed action.

In this way, a method is implemented in which information is stored as part of the action taken, for example, to provide information about which deviation has been detected, who belongs to the associated manufacturing personnel and how one or more persons in charge of these production personnel have been notified.

In addition, the information data may further include, for example, what steps have been performed by the manufacturing personnel responsible to optimize the manufacturing so as to automatically obtain information about an effectiveness of the action taken. By means of storing the information data, a protocol can thus be created that includes all information that is relevant in the context of production.

Examples of a memory in which this information data is stored are a hard disk space, mobile storage media, but also databases such as a backend of a server.

According to a further embodiment of the first aspect, the execution of a respective predetermined action comprises a comparison of stored data which are stored in the first memory or a further memory.

In this way, it is realized in the context of the method that stored data is matched with predetermined data in order to obtain, for example, a consistency of the stored data. The stored data comprise, for example, the previously described information data which was stored in the first memory in the context of the method, but possibly also historical data which was stored in the first or another memory in the course of the production at an earlier time and the received one Signals and / or the action performed are assigned. Thus, a contribution is made to unify already stored data and current or future stored data and thereby contribute, for example, to a globalization of libraries.

According to a further embodiment of the first aspect, the execution of a respective predetermined action comprises outputting multimedia data which includes information about the execution of the respective predetermined action.

This method makes it possible, for example, to visualize the action to be carried out, for example in order to inform responsible production personnel about the determined deviation. For example, such an indication can also be made by means of an acoustic signal. For example, the manufacturing staff is indicated on a display by means of a green flag that the production is optimized and runs within the predetermined threshold values and tolerance ranges. If, however, no agreement of the received signals with the predetermined threshold value or values has been determined, this deviation can be signaled to the manufacturing personnel by means of a red flag, for example. Alternatively or additionally, the manufacturing personnel can be signaled a detected deviation by means of a flashing light.

Embodiments of the invention are explained in more detail below with reference to schematic drawings. Show it:

1 exemplary representation of a process for production optimization in the form of a flowchart,

2 a further flowchart for illustrating the method,

3 a screen shot of the process,

4 another screen shot of the process,

5 another screen shot of the process,

6 another screen shot of the process,

7 another screen shot of the process,

8th another screen shot of the process,

9 another screen shot of the process,

10 another screen shot of the process,

11 another screen shot of the process,

12 another screen shot of the process,

13 another screen shot of the process,

14 another screen shot of the process,

15 another screen shot of the process,

16 another screen shot of the process,

18 a further flowchart for illustrating the method,

19 another screen shot of the process,

20 a further flowchart for illustrating the method,

21 another screen shot of the process,

22 another screen shot of the process,

23 another screen shot of the process,

24 another screen shot of the process,

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30 another screen shot of the process,

31 another screen shot of the process,

32 a further flowchart for illustrating the method,

33 a further flowchart for illustrating the method,

34 a further flowchart for illustrating the method,

35 a further flowchart for illustrating the method and

36 another flowchart illustrating the method.

Elements of the same construction and function are identified across the figures with the same reference numerals.

1 shows a flowchart for a method that is suitable to easily optimize a production. As part of the method, signals are received which include information about a quality of manufacture, and a match is determined in dependence on the received signals and at least one predetermined threshold value. If a match and consequently no deviation are determined as a function of the predetermined threshold value or values, there is no reason to influence the production. This is then done, for example, as desired within certain tolerance ranges, which are defined for example by means of the predetermined threshold values. However, if no agreement was found and consequently a deviation is determined, a given action is carried out in each case in order to optimize the production and to align it purposefully. The predetermined action to be performed is assigned to the received signals and the at least one predetermined threshold value and may include, for example, a notification of production personnel or a visualization of the deviation.

In this context, the flowchart in FIG 1 For example, a main view of a system capable of realizing the method of optimizing manufacturing. In this case, different module groups or module branches are illustrated, which perform various tasks and functions in the context of the method. Here are module groups with the reference numeral 10 stand alone module groups, while the module groups with the reference numeral 20 Branching on other modules or have crucial properties. Furthermore, it is a module group 30 illustrated, which is in a validation phase or has been completed.

The illustrated exemplary system, which enables implementation of the described method, will be referred to in the further description as DDM, which is an abbreviation for the English term "DPMO based deviation monitoring". A translation of this English phrase is given by "monitoring deviations based on defects per million possibilities".

Such a system comprises, for example, more than 20 software modules which automatically collect, prepare and display necessary data from received raw machine data and data exports in order to update a current quality every minute, for example, and trigger actions or a chain of actions in the event of deviations from predetermined threshold values. For example, in cooperation with associated production personnel, deviations determined are analyzed and appropriate countermeasures initiated in order to optimize the production by means of the illustrated method.

For example, such an automated system connects and monitors a production line's performance through in-depth signals that include information on the quality of production, thereby monitoring key metrics as well as human actions taken by the company Manufacturing personnel to monitor or verify deviations from the predetermined thresholds. For example, the system is database-based and automatically logs and thus automatically stores all relevant information about deviations, including, for example, failure images that can be associated with deviations, and the actions and actions taken and / or performed as a result of the deviations determined.

The DDM realizes an action reporting system, which includes mechanical and human actions on deviations of a production line, for all hierarchies of a production (operator, technician, cost center manager, quality inspector, work preparation, factory management). Advantages of the presented system include automatic transparency and thus non-modified and immediately traceable information provided, which improves the necessary steps regarding quality, productivity and performance of a production line.

As a result, it is not necessary, among other things, to carry out a complex search for information, for example in the event of a failure, which until now has not been detected very late or even at all. In this context, relevant information is automatically organized and provided by the system. In addition, cross-departmental human incompatibilities and misunderstandings in an information exchange. The information relevant in this context will be provided by the system online, without delay and on time and, where appropriate, across departments, in order to allow complete transparency.

Such a system thus allows the manufacturing personnel involved to deal exclusively with an improvement in the quality of production in terms of their productivity in the context of manufacturing. In addition, a static exchange of information, for example, from person to person or mail or by meeting bypassed.

2 FIG. 11 shows another flowchart for illustrating the method in which basic steps of the method are illustrated.

3 shows an embodiment of a screen display in the context of the method and illustrates, for example, a first step for monitoring deviations in the context of a DPMO value curve of a front end of the DDM system. In this context, for example, a time interval 40 can be adjusted to represent an hourly, daily, weekly and monthly value history in this embodiment.

4 shows another screen representation of the first step to monitor deviations in the DPMO value history at the front end of the DDM system, which indicates that a production line 50 is eligible for a DPMO value history 60 is displayed graphically.

As part of the DPMO value history, for example, the following information is provided or determined at the frontend: DPMO values are calculated, for example, according to a standard. This includes, for example, DPMO calculations for electronics production.

The frontend includes DPMO value histories for hourly, daily, weekly, and monthly time intervals.

By selecting the time interval and the production line, a corresponding value course of the DPMO is graphically displayed.

In the illustrated DPMO value course, a value of zero indicates no defect; in contrast, no DPMO value is given if the production line stagnates, for example.

In this context, the last point of the DPMO value history represents the last value of the selected time interval.

5 shows a further screen representation of the method in which information in connection with the DPMO value history of the front end are illustrated. Compared to the 3 and 4 are in the screen view of the 5 further areas marked, for example, executable functions 70 for saving, sending and printing. In addition, a mathematical representation 80 for example, to calculate DPMO values according to a given standard. Furthermore, by the reference numeral 90 specified an adjustable DPMO limit, which is shown in this embodiment with a value of 9 DPMO.

In 6 FIG. 2 illustrates an exemplary second step of the method for monitoring deviations that presents information about an analysis of a deviation on the front end of the DDM system. In this context is another time interval 100 adjustable.

In 7 is another screen display of the second step is shown, in which a choice is given, it allows, as sub-point of a production line, an inspection plan 110 select.

8th shows another screen presentation of the second step to monitor deviations and to analyze the deviations, in addition to the time interval 100 as subitem of the selectable inspection plan 110 a Pos.ID 120 is selectable. In addition, there are errors 130 illustrated.

9 shows another screen shot of the second step, in addition to the production line 50 , the time interval 100 , the inspection plan 110 and the POS.ID 120 one out of the error pictures 130 selected enlarged error image 140 is shown. In addition, information 150 with respect to the enlarged defect image 140 specified.

An analysis of the deviations comprises, for example, the following information that can be displayed on the front-end of the DDM system: According to a deviation of the DPMO value, an analysis of the deviation is possible, which includes information about real classified defect images of a reparation station.

Due to a potentially large amount of error patterns, the analysis of the deviations includes hourly and daily time intervals to allow for faster closed loops and allow shorter load times for analysis of the system.

In the analysis of deviations, selecting the date and time with respect to the date and a time selector allows you to view a particular history of an analysis of a variance in the past.

By selecting the inspection plan 110 will be information related to the selected inspection plan 110 displayed. This information includes, for example, a project name, date and time, as well as total and defect inspected boards with associated percentages and total and defect counter values for components and, for example, solder joints with associated calculated PPM (parts per million) values.

By selecting a defect image in a list of defect images 130 become information 150 with respect to the selected defect image. This information 150 For example, a data matrix, a component ID, a shape and features of the reparation station and an inspection system have been detected at the error.

10 shows information related to the analysis of deviations that the information of the 6 to 9 include and beyond information or executable functions 160 to save and print include. In addition, the screen display includes the 10 information 170 of the inspection plan 110 as well as the possibility to select a data review 180 regarding an associated date.

11 FIG. 12 is another screen illustration of an exemplary third step of the deviance monitoring method, which includes application and usability features. In this context, it is possible to have a production line 50 in a data tree, such as an hourly bar chart 200 is displayed for a previous day.

In this context, the application and usability in the third step of the method includes, for example, the following information that can be displayed on the front-end of the DDM system: For example, in terms of application and usability, the bar chart becomes 200 calculated on the basis of a comparison of time cycles of an integrated inspection system in the production line 50 and calculates the data for the slowest inspection system. Such an approach detects, for example, whether a bottleneck or bottleneck exists in the integrated inspection system.

In the bar chart 200 the selected production line 50 For example, bars indicate in a green color that something is available or usable by the slowest inspection system, and the residual value of this bar indicates, for example, a potential applicability.

In the bar chart 200 For example, a timeline also shows a series of the inspected project that includes information about the inspected project, a name of the inspection plan, a set of boards that have been inspected, and a set of boards that may possibly be controlled based on calculations a residual time related to the time cycles of the project.

Possible colors of the bars in the bar chart 200 are for example selected as follows: green represents an availability, gray represents an unknown stagnation and a violet color, for example the last bar in the displayed screen 200 having, represents an average availability based on the day.

For example, orange bars appear when there are entries for the bars with unknown stagnation. Such entries may be made, for example, in selectable files, such as an export folder in terms of application and usability.

12 shows another screen in terms of application and usability with information about a production line 50 as well as an inspection plan 110 as well as functions 160 For example, to save, send and print the selected file and other information 190 about the inspected project and a graphical representation of the bar chart 200 , which includes usability and usability information, and a choice 210 a representation of the bars as a percentage or in minutes.

With regard to a message and system display in the event of exceeding a DPMO limit, for example, the following information is provided:
A backend system of the DPMO-based system for the automatic monitoring of deviations automatically sends messages at hourly intervals, for example via e-mail and system displays if a DPMO limit is exceeded.

In XML-selectable files, information may be stored, including, for example, e-mail information about manufacturing personnel responsible for the particular production line 50 and thus associated therewith and, for example, system IP information that may be displayed as monitoring information of the system.

For example, the notification mails contain information about the name of the production line 50 with an associated DPMO boundary crossing, the DPMO value and a link which automatically opens an analysis of the deviation, which includes information of the classified error of a reparation station, which was responsible, for example, for exceeding the predetermined DMPO limit.

System notifications are displayed, for example, on one or more screens of the production line and inform in this way associated manufacturing personnel of the production line that a DPMO limit is exceeded, for example, the ability to provide additional manufacturing personnel, such as a technician to inform, but also by means of a Email is notified. In this way, for example, there is a double assurance of informing that a production line has exceeded a given DPMO value.

13 shows another screen display, which includes information about an email notification, for example, if a DPMO limit 90 was exceeded. Among other things, this screen is a name 220 the production line and an exceeded DPMO value 230 specified. In addition, a link 240 which makes it possible to open information about an analysis of the deviations on the frontend.

14 shows another screen display, which includes information about a system notification, for example, exceeding a predetermined DPMO limit 90 , In this screen is the name 220 the production line, the exceeded DPMO value 230 and information 250 containing information to inform responsible manufacturing personnel, for example, with a given telephone number.

In summary, with the previous figures, a DPMObased system is described which realizes automatic monitoring of deviations which, by means of displays and notifications, makes it possible to detect and / or track deviations determined almost without time delay, among other things a timely correction of the respective ascertained Deviation by means of executable actions allows.

All information, data and images are collected and calculated by a backend of the DDM system, which thus provides, for example, the final data for the frontend of the system and for presentation as in the previous ones 1 to 14 exemplified.

In the following 15 to 36 A further exemplary embodiment of a DPMO-based system for monitoring deviations is described in which a line performance observer is reacted with actions for deviations which, for example, react to real-time errors based on Jidoka functions.

15 shows a screen view of the lines performance observer with actions on deviations including Jidoka detection on real time errors.

16 shows another screen presentation of the line performance observer.

18 shows a software architecture in the context of a flowchart of the line performance observer with actions on deviations including Jidoka detection for errors.

The Line Performance observer with actions on deviations including Jidoka detection for real errors has the following modules and / or information:
DPMO calculation and presentation in an hourly process (16 hours) including specified or predefined lower and upper limits.

Presentation of a capacity calculation by modules including bottleneck detection in hourly representation of a bar chart, for example (24 hours).

Display of failure images including information such as data matrix, analysis time, position, design, plan, module, feature and so on.

Calculation and representation of a placement performance as well as trend indication of placement performance on cumulation, for example, from 0 o'clock one day to the current hour.

Jidoka detection based on three consecutive positional failures (configurable by the same or different characteristics).

Representation of a line status and information by means of flags, in production without deviation, for example in green, in production with deviation, for example in red, for maintenance or repairs, for example in yellow and other other downtime, for example in color blue.

19 shows another screen representation of the line performance observer, which includes information about an action. In the case of a deviation for the values to be monitored (DPMO, Jidoka, etc.), the process with the deviation type and all relevant information and failure images is stored in a process database and a line-responsible SMD technician and, for example, a deputy are sent by means of e-mail via the Process or the deviations determined.

20 shows another flowchart with information on the line performance observer and exemplary measures for defined processing steps by an SMD technician.

A summary of information and the operation of the Linien Performance Observer with actions on deviations including Jidoka detection on real errors includes:
Automatic data integration and system update, for example, every three minutes.

Monitoring quality and automatic intervention in case of deviations.

Documentation of processes and / or deviations with all relevant information and selection images.

Transparent presentation of line performance and integration of involved employees or assigned production personnel regarding the quality and defined goals of production.

On the basis of the stored processes in a process database, long-term successes of the executing or executed measures can be assessed with regard to their effectiveness.

Continuous improvement process of quality and continuous optimization of use and resources in manufacturing.

In the following figures, a DDM lines performance observer with actions on deviations including Jidoka on real error detection is described.

21 shows a screen shot of the DDM lines performance observer.

22 shows another screen shot of the DDM Lines Performance Observer and a DPMO module. Shown is a graphical history 260 of the DPMO (Defects Per Million Op- tunities, German: Defects Per Million Opportunities), and is a unit of measurement commonly used in Six Sigma, and refers to the number of errors or defective units per million units considered (potential for error).

In the example diagram, the hourly DPMO history 260 presented over the last 16 hours.

The illustrated lines in the diagram symbolize an upper limit of intervention 270 , a lower limit of intervention 280 ,

Numbers are displayed differently depending on the DPMO value and the intervention area.

23 shows an embodiment of a utilization module of the DDM lines performance observer. Boxes symbolize line modules (test modules), where 290 the slowest module symbolizes while 300 the fastest module symbolizes.

This screen shows a graph showing the hourly utilization percentage over the last one 24 Represents hours.

The illustrated lines in the diagram symbolize the upper limit of intervention 270 and the lower limit of intervention 280 ,

In timelines, the current project is displayed with actual or from cycle times highly calculated target piece number information.

24 shows a further screen presentation and an embodiment of a focus module of the DDM lines performance observer. It is information 305 presented concerning a currently running project, such as period, plan name, benefit (target / actual percent), EP, components, LS and information of a selected failure image such as: data matrix, position ID, design, the entered feature at the analysis site, attachment ,

In a picture bar 310 losses (real errors) of the last eight hours are displayed.

A selected picture 320 is shown enlarged in this screen. For example, a double-click on the large image automatically makes a further enlargement.

25 shows another screen representation, which represents an embodiment of an information panel DDM lines performance observer. A currently running project is displayed as a heading.

Next follow: DPMO, placement performance, FPY, pick-up security, target areas, value fields marked with colors, for example green (is a value in the target area), while red is for example (a value above the target area or the target value).

In addition to the placement, for example, from 0 o'clock to the current hour, a number of the assembled components are cumulated, including, for example, colored trends, for example by means of a green arrow or a red arrow.

26 shows an embodiment of a line status in another screen display of the DDM lines performance observer.

A status of the line is represented, for example, by means of a flag. For example, a green flag indicates that the line is running without any deviations.

For example, a red flag indicates that the line is running, but that deviations in the monitored features have been detected.

For example, a blue flag signals that the line is not producing and / or there is an unknown deadlock (repair, missing parts, and so on).

For example, a yellow flag indicates that maintenance is being performed in the line.

In this context, for example, a maintenance status is set manually, while the previously mentioned remaining status flags are set automatically.

27 shows a further screen representation of the DDM lines performance observer and in this embodiment, a screen display of an action module. A current production line is displayed as a heading. Performance characteristics (DPMO, placement performance, FPY, pick-up security, Jidoka) are indicated in this context and are displayed with a mail symbol.

A blue color of the symbol indicates that the feature is being tracked.

A gray color indicates that the feature is not automatically tracked.

A red color indicates, for example, that a technician is automatically informed about a deviation by e-mail.

The bottom of the screen shows a timestamp of the last update and its duration in seconds.

The illustrated and described DDM system of the line performance observer includes, for example, the following information and / or actions and / or functions and / or advantages:
Improvement of action processing by SMD technicians (fixed distributor),
System improvement and debugging,
new module to review and check the effectiveness of actions,
Scope according to the new module,
Status Conclusion,
Status improvement,
current schedule,
Visions (future expansion).

• 1. Die Ermittlung der Techniker anhand der letzten Log-in in einem ADDS-Server (Arbeitsplatzrechner).
• 2. Ermittlung der Techniker anhand eines Schichtplans.
• 3. Ermittlung der Techniker anhand der Stechzeiten an zugehörigen Stech-Terminalen.

With regard to improvements in action processing by, for example, manufacturing personnel or technicians, the following is pointed out:
In order to avoid unnecessary sending of e-mails and to reach those directly responsible, it is necessary to inform only the currently present technicians of the DDM system with abnormalities. For example, there are three possibilities:

• 1. The determination of the technicians based on the last log-in in an ADDS server (workstation).
• 2. Determination of the technicians on the basis of a shift schedule.
• 3. Determination of the technicians based on the lancing times at associated lancing terminals.

Notification of the present technicians via ADDS includes, for example, the following actions or information:
The determination of the present technicians by the credentials on an Active Directory server service, which stores the information of the user when logging on to his workstation plus eight hours (a working time that a technician spends on schedule in the company), then the emails to send.

In this context, the reference book Wiki: Active Directory (Active Directory) means that the directory service of Microsoft Windows Server (as of version Windows Server 2008) is called the core component as Active Directory Domain Services (ADDS). A Directory is an assignment list, such as a phone book that maps phone numbers to their respective ports, to owners. Among other things, the information of the last log-in is saved by a user.

However, this possibility of determining via ADDS through the last log-in may not lead to the desired result because: Technicians can not log in and log out of their workstations and technicians on multiple computers every day and also in different logon servers.

For example, from a root server, a company operates more than 340 logon servers in which users can log in. Finding users (for example, more than 20 technicians) when they last logged in to the ADDS server service across all of these logon servers takes a relatively long time to send a notification afterwards.

28 shows another screen presentation that includes information about a notification of present technicians via SP. The second possibility is to determine the technicians based on a shift plan, which is edited manually by different users and is available for example in the form of an Excel file.

It can be seen from the screen display shown that there are no defined predefined and / or uniform names when naming the paths and the files.

29 shows another screen presentation, which includes information about a notification of technicians present by means of a shift schedule. Even with such an exemplary Excel file everything is set up manually and can be completely changed by the respective user at any time.

It is possible to integrate such an Excel file in the program code via an Excel interface so that technicians can be identified and in which layer they are present. It is advantageous if a naming of the paths and a structure of the tables are defined defined, so that no manual change takes place, which may not be automatically detected by a software.

Determining a technician based on sting times includes the following information and / or actions: As a third possibility and is available that technicians are determined by means of lancing times at associated stanchion terminals. The structure of a program structure is unknown, but information can for example be stored in a structured manner in a database, for example, provide information about when a technician comes to work and when he leaves it again.

Such information could be queried via a modulated interface in a program so that only present technicians can be reached with notifications.

Furthermore, illnesses or absences that have suddenly occurred can lead to problems that, for example, could not be intercepted in good time by means of a manual entry in a shift schedule.

For example, it is advantageous if a lancing database can be accessed programmatically, which enables a robust interface for the DDM system, which can not be influenced by manual inputs.

In this context include system improvement and troubleshooting For example, the following information and / or actions:
Processing a measure on the Line Performance Observer (LPO), for example, in the middle of a production line by a technician can lead to delays in processing a measure because, for example, a software module of the LPO is updated every three minutes and If necessary, a technician may not make a selection for further steps of the action for a few seconds during this time.

By means of a Boul value, which is implemented for example in the various software modules, it can be determined whether a technician is currently processing a deviation, so that for a period of processing the update of the software module is overridden. However, this applies, for example, only to the LPO module to be processed, for example in a middle of the production line, where the technician in charge is currently processing the detected deviation, while updating the LPO in the aisle (for example a large display for visitors) is updated and continues to go unnoticed is running continuously.

After processing a deviation by a technician, a function is executed which, for example, automatically sets a large status flag of the production line to the color green immediately or at the latest at a next update of the LPO which is less than three minutes.

A deviation for DPMO calculations makes sense only in this context, if the production line has manufactured at least for example 50% for the last hour, since otherwise a number of opportunities are too small to calculate a meaningful DPMO value, to this as a deviation to declare.

For this reason, among other things, the described system involves optimizing the relationship between a calculated DPMO value, usage and placement internally in the program code so that a major deviation can be detected for the first time because, for example, technicians were not notified to resolve any occurring deviations ,

Such optimization, for example, may later be affected by set bits in XML module configurations, depending on how a failure rate is moving.

Among other things, the system includes a new module to review and verify the effectiveness of an action. In this context, the following information and / or actions are given:
For example, when an action is performed by a technician due to abnormalities, it is not enough for them to be executed only and stored in a database as records, but it is advantageous to visually represent such anomalies and / or other information, and thereafter To be able to check purposeful processing and effectiveness and possibly initiate further steps and / or actions.

For this reason, inter alia, the described system comprises a new module which fulfills the functions described above in order to expand the wishes and requirements of, for example, a production management and an executive technician. Such a module can be continuously improved.

By means of the new module, conspicuous abnormalities are displayed, for example, in a kind of matrix, layers with respective times being represented, for example, as rows of this matrix and production lines, for example, as columns.

Further, abnormalities are represented as squares (labels) in the matrix with a deviation type (DPMO, Jidoka, and so on) as a label, for example.

If, for example, a conspicuity has been processed by a technician, the label is displayed, for example, with a green background color. Otherwise the conspicuousness was not processed and a background color of the label is shown as red, for example.

In this context, for example, each of the three layers of the last 24 hours are automatically displayed and it is also possible to display any days based on a date selection.

On the basis of such described representations of the abnormalities and possibilities for carrying out, for example, actions, an optimal overview is made possible which, for example, enables a technician to analyze the events in a previous shift and to check the effectiveness of measures and / or actions taken.

30 shows another screen presentation that includes information about the new module described above to review and verify the effectiveness of an action. This screen presentation includes information 340 on the representation of production lines as Columns of a matrix, further includes this screen presentation of information from layers 350 with respective times as rows in a matrix as well as examples of unhandled abnormalities 360 , which are displayed with a red background color, for example, and examples of processed abnormalities 370 which are displayed, for example, with a green background color. Furthermore, for example, information 380 indicated on series of abnormalities of a production line, which are easy to detect and thus appropriate action can be taken. In addition, there is the possibility of a selectable date 390 ,

31 shows another screen presentation in which further information about the new module for reviewing and checking the effectiveness of an action are shown. This information includes, for example, title information 400 with a variance type, a timestamp, and a completion status.

There are also automatically generated information 410 to the respective deviation represented by the DDM system. Under the reference 420 For example, information on the action taken, for example carried out by a technician, is presented for the identified deviation. Furthermore, information 430 an assigned manufacturing personnel, such as a technician, presented, who edited the measure or has. In addition, the screen display shown comprises an image list 440 with images that led to the deviation or that are assigned to the deviation. For example, with a mouse click of a computer mouse into a respective failure image an information display of failure information 450 and enlarging the dropout image 460 possible, which is shown in the screen shown in the upper right area.

For example, by double-clicking a computer mouse on the selected and enlarged dropout image 460 this can be increased several times and displayed, for example, on a separate computer window in order to better analyze the respective failure image.

Furthermore, there is a picture box 470 which serves as a placeholder for later implementations of a module of quality data, for example, presented in the form of time-dynamic traces, so as to discern improvements or deteriorations of this product for the selected time.

• – Backendmodule aus den Eingangsquellen berechnen Daten und bereiten diese vor für das LPO-Modul (englisch: Line Performance Observer, deutsch: Linien Performance Beobachter).
• – Das LPO-Modul zeigt in Abhängigkeit vorbereiteter Daten die Performance an einem Bildschirm an und zeigt die Abweichung zu vorgegebenen festgelegten Schwellenwerten an, und speichert ermittelte Abweichungen mit zugehörigen Ausfallbildern und benachrichtigt zuständiges Fertigungspersonal, wie zum Beispiel Techniker beispielsweise via E-Mail.
• – Ein zuständiger Techniker hat daraufhin die Möglichkeit, auf die ihm zugesandte Benachrichtigung zu der jeweiligen Abweichung sofort zu reagieren und diese online, beispielsweise mit einigen wenigen Klicks einer Computermaus, zu bearbeiten, während beispielsweise das Produkt und/oder die Produktionslinie läuft und beispielsweise Leiterplatten mit dem Ausfallbild noch in der Produktionslinie vorhanden sind.
• – Das neue Modul des Aktionsberichtswesen stellt somit eine Übersicht für Techniker dar, die Abweichungen, Maßnahmen und Informationen umfasst, die vorher in einer Produktionslinie aufgetreten sind, um nachzuvollziehen, ob diese eingeführten Maßnahmen wirksam sind.
• – Des Weiteren wird eine Übersicht beispielsweise für eine Produktionsleitung der Produktionspools zusammengestellt, um eine Qualität und Eckdaten einer Produktionslinie einsehen zu können sowie einen Zustand der Aktionsbearbeitung durch den Techniker.
• – Des Weiteren ist es möglich, eine Übersicht für Abteilungen der Arbeitsvorbereitung zusammenzustellen sowie der Qualitätssicherung, die an den Abweichungen und/oder Maßnahmen beteiligt sind.

The DDM system includes, for example, in connection with the new module, the following information and / or actions: Through the new module of an action reporting system, the DDM system is set up so that the following steps occur automatically:

• - Backend modules from the input sources calculate data and prepare it for the LPO module (English: Line Performance Observer, German: Linien Performance Observer).
• The LPO module displays the performance on a screen as a function of prepared data and displays the deviation from predetermined fixed thresholds, and stores detected deviations with associated failure images and notifies responsible manufacturing personnel, such as technicians via e-mail, for example.
• - A responsible technician then has the opportunity to respond immediately to the message sent to him for the deviation and to edit them online, for example, with a few clicks of a computer mouse, while, for example, the product and / or the production line is running and, for example, with PCBs the failure pattern are still present in the production line.
• - The new module of the Action Reporting system thus provides an overview for technicians that includes deviations, measures and information that have previously occurred on a production line in order to understand whether these measures taken are effective.
• - Furthermore, an overview is compiled, for example, for a production management of the production pools, in order to be able to see the quality and basic data of a production line and a state of the action processing by the technician.
• - Furthermore, it is possible to compile an overview for departments of work preparation as well as quality assurance, which are involved in deviations and / or measures.

• 1. Das ganze automatisierte System verbindet und überwacht die Performance einer Produktionslinie anhand der beschriebenen Schnittstellen für die wichtigsten Kennwerte und ebenfalls humaner Aktionen, die betätigt wurden auf Abweichungen zu den festgelegten Grenzwerten.
• 2. Das datenbankbasierte Automatische protokolliert und speichert alle relevanten Informationen über die Abweichungen, inklusive der Auswahlbilder, die zu diesen Abweichungen geführt haben oder diesen zugeordnet sind und die Maßnahmen, die zu dieser Abweichung durchgeführt wurden.
• 3. Durch das neue Aktionsberichtswesen schließt in diesem Punkt das DDM-System so ab, dass alle maschinellen und humanen Aktionen auf die Abweichungen einer Produktionslinie für alle Hierarchien einer Fertigung (Bediener, Techniker, Kostenstellenleiter, Qualitätspersonal, Arbeitsvorbereiter, Werksleitung) automatisch, transparent, nicht modifiziert und nachvollziehbar zur Verfügung gestellt werden, um die notwendigen Schritte bezüglich Qualität, Produktivität und die Gesamtperformance einer Produktionslinie zu verbessern.
• 4. Im Rahmen dieses Systems ist es folglich möglich: – dass eine aufwändige Suche nach Informationen entfällt bei einem Ausfall (der bisher selbst erst sehr spät oder gar nicht detektiert wurde), diese wird automatisch durch das System organisiert und Informationen werden zur Verfügung gestellt. – Des Weiteren entfallen ableitungsübergreifende humane Inkompatibilitäten und Missverständnisse bei beispielsweise einem Informationsaustausch, da relevante Informationen mittels des Systems und/oder des beschriebenen Verfahrens online ohne zeitliche Verzögerung und zur richtigen Zeit (englisch: just on time, JIT) abteilungsübergreifend vollkommen transparent zur Verfügung gestellt werden. – Das System stellt allen Beteiligten einer Fertigung die Möglichkeit in Aussicht, sich ausschließlich mit der Verbesserung der Qualität und Produktivität zu beschäftigen.

In summary, the following information regarding the DDM system is given:

• 1. The whole automated system connects and monitors the performance of a production line based on the described interfaces for the most important parameters and also human actions that were actuated to deviations from the specified limits.
• 2. The database-based automatic system logs and stores all relevant information about the deviations, including the selection screens that led to or are assigned to these deviations, and the measures that were performed for this deviation.
• 3. The new action reporting system concludes in this point the DDM system so that all mechanical and human actions on the deviations of a production line for all hierarchies of a production (operator, technician, cost center manager, quality personnel, work preparer, factory management) automatically, transparently, unmodified and comprehensible to improve the necessary steps in terms of quality, productivity and overall performance of a production line.
• 4. In the context of this system, it is thus possible to: - avoid a time-consuming search for information in the event of a failure (which until now has been detected very late or not at all), which is automatically organized by the system and information is made available. - Furthermore, cross-human incompatibilities and misunderstandings in, for example, an exchange of information, since relevant information by means of the system and / or the described method online without delay and at the right time (English: just on time, JIT) are provided across departments completely transparent , - The system offers everyone involved in manufacturing the opportunity to focus exclusively on improving quality and productivity.

• – Abteilungsübergreifend ohne Zeitverlust bei der Suche nach Informationen Ausfallbilder, und so weiter.
• – Abteilungsübergreifend ohne Zeitverlust bei fehlenden oder nicht ausreichenden Informationen über die Ausfälle bei den Informations- und Qualitätsbesprechungen, denn diese stehen automatisch über das Berichtswesen zur Verfügung.

In this context, the following improvements of the DDM system are still possible, which have already been indicated in the context of the illustrated system:

• - Interdepartmentally without wasting time in finding information about failure pictures, and so on.
• - Interdepartmentally without wasting time on missing or insufficient information about the failures at the information and quality meetings, as they are automatically available through the reporting system.

Interdepartmental no time losses at event to actions in mitigation measures, because the system notifies the responsible or responsible staff or technical staff directly and expects a corrective action. If a responsible employee can not do this without the help of a border area, this process is forwarded by a technician including all information in this border area.

Across departments, all local and personalized manual maintained combinations (such as Excel lists, Access databases, Power Point presentations, Word forms, etc.) are eliminated by various organizational staff.

Across departments no time wasted on unnecessary e-mails about failure information or saving on printing the entire range of information or printing the manually maintained documentation.

In this way, it is possible, for example, to save more than 20% of the working time previously required to deal with and deal with the abovementioned points on average across all staff departments.

The presented described system therefore makes it possible to avoid these time losses and represents an advantageous and online-enabled information and action flow.

32 shows another flowchart for illustrating the method, which includes information about a current flow of the DDM system.

33 shows another flowchart for illustrating the method, which includes future possible extensions of the DDM system.

34 shows another flowchart for illustrating the method, which includes an overview of various modules of the DDM system.

35 shows a further flowchart for illustrating the method, which includes an overview of other different modules of the DDM system.

36 FIG. 11 is another flow chart illustrating the method including the example structure of a module of the DDM system.

Claims (5)

 Method for optimizing a production, comprising Receiving signals that include information about a quality of production, Determining a match as a function of the received signals and at least one predetermined threshold value, - Execute a respective predetermined action for optimizing the production, if no match was determined in dependence of the received signals and the at least one predetermined threshold value. The method of claim 1, wherein performing a respective predetermined action comprises notifying manufacturing personnel associated with the at least one predetermined threshold and / or the respective predetermined action. A method as claimed in claim 1 or 2, wherein performing each predetermined action comprises storing information data in a first memory which includes information about the action being performed. Method according to one of claims 1 to 3, wherein the execution of a respective predetermined action comprises, matching stored data stored in the first memory or a further memory. Method according to one of claims 1 to 4, wherein the execution of a respective predetermined action, outputting multimedia data, which includes information about the execution of the respective predetermined action.

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