Enabling Tier 1 suppliers to achieve OEM-level traceability and quality

Traceability enables product recalls to be facilitated more quickly by providing data on a component’s origin and assembly quality assurance.  Without this data, manufacturers may need to recall a greater number of vehicles than necessary, increasing costs.

As a result, Tier 1 suppliers must meet traceability and quality standards to align with OEM requirements by ensuring product quality, safety and regulatory compliance throughout the supply chain while maintaining cost-efficiency.  This involves tracking and documenting raw material history, sub-assemblies and finished products, including identifying specific batches and manufacturing processes.

To achieve zero-defect assembly and full production oversight requires the design of processes which prevent errors from occurring, or securing an error once detected and rectifying it at the source.  Error-proofing and data tracking keeps quality in check and applies to every stage of a manufacturing process.

Error-proofing steps include:

• Reducing human error by introducing process control and automation.
• Securing errors by giving the operator clear feedback on where it occurred, so they can correct it.
• Utilising assembly tool interlock and line control to prevent tools being used on the wrong product.
• Introducing Industrial Location Guidance technology to safeguard against operator error or oversight.
• Implementing Human-Machine Interfaces (HMIs), which connect an operator to the process they are undertaking.

Error-proofing and traceability are key elements of Atlas Copco’s Smart Integrated Assembly concept for manufacturers looking to implement smart manufacturing.  Encompassing Atlas Copco’s assembly tools, hardware, software and service solutions, Smart Integrated Assembly provides value in each element of the manufacturing cycle.  This results in more efficient, flexible processes which maximise uptime and reduce waste and energy consumption.

Atlas Copco’s offering for Tier 1 suppliers provides a fully scalable solution that helps them to stay ahead in their assembly processes:

• Joint Fastened – Meet OEM traceability & quality expectations, reduce downtime and defects, automate and optimise high-volume fastening operations.
• Station Controlled – Ensure repeatable and defect-free production, meet OEM quality & safety standards.
• Station Automated – Boost production output and maintain quality, reduce costs and improve efficiency through automation.  OEM compliance with traceability and repeatable processes.
• Line Connected – Eliminate inefficiencies with real-time production data.  Provide full OEM traceability.
• Factory Integrated – Unify all production elements into a single efficient system.  Ensure OEM compliance, increase throughput and minimise downtime.

As manufacturers transition from cable to cordless tools in production to increase flexibility, they face the challenge of battery tools not being physically coupled to a specific workstation.  Atlas Copco’s Industrial Location Mapping (ILM) tool management system answers this challenge by ensuring that tools only operate in the correct location at the right time.

Safeguarding assembly quality requires a bolt-level positioning system that allows for sequence tightening and visual operator guidance, as well as the utilisation of multiple tightening programs.  Using vision technology, Atlas Copco’s Industrial Location SpotPoint 2.0 (ILS 2.0) offers a wireless bolt-level positioning system that reduces tightening errors.  Applications for ILS 2.0 include EV battery assembly, as well as powertrain, offroad engine and seat assembly.

While many steps in production are already highly automated, there are still activities in assembly and quality assurance that require manual rework and operators to switch between different product lines.  Based on dynamic laser and video projection, Atlas Copco’s Projection Guidance Solutions replace conventional assembly templates with digital versions that provide intuitive worker guidance.

Atlas Copco’s Avantguard process control software provides the ultimate solution in error-proofing that achieves efficiency and product quality for manufacturing operations.  Avantguard controls the assembly process by connecting to the tools and machines on the production line, ensuring they are activated at the right time with the correct tightening programme.

By embracing smart manufacturing and advanced error-proofing and quality assurance technologies, Tier 1 suppliers can meet the needs of OEMs and position themselves for future success as supplier partners of choice.  Smart manufacturing provides competitive advantage by allowing for flexible production and informed decision-making to meet evolving OEM customer needs.

Atlas Copco is developing Tier 1 supply chain agreements into long-term strategic business partnerships that provide scalable solutions and support that enables them to ensure sustained growth.