In the manufacturing industry, time is a critical factor; therefore, manufacturers continually seek ways to improve efficiency and cut costs, all while enhancing customer satisfaction. So, when rework impacts your assembly, causing disruptions such as line stoppages and recalls, you want to get your line back up and running at full capacity.
Easier said than done, right? Well, not when Avantguard collaborates with your operators to ensure mistakes aren’t overlooked, both in assembly and rework stations. This way, Avantguard can help lower the risk of line stoppages by first reducing errors in real-time, and then by enhancing the rework process with step-by-step instructions and feedback. With Avantguard aligning with your rework strategy, whether that is in-line, off-line, or end-of-line, it can help to reduce the effects of downtime and repairs, enabling you and your operators to stay on track and productive.
Are you ready to significantly reduce your risk of errors and line stoppages? Read on to discover the advantages of using Avantguard in production, enabling you to improve efficiency and reduce costs with a straightforward solution.
What is the actual cost of downtime?
Incorrect repairs make up a good portion of product recalls and safety issues, which is why having a reliable error-proofing solution beside your operators, guiding them through assembly processes and alerting them to errors as they occur, is more important than ever.
Errors are inherently human, and as long as we have human operators, occasional mistakes are inevitable. But it isn’t just our operators we should look out for. Our automated solutions can also cause errors and rework if a part is failing or needs maintenance, the part is on back order, or if the solution is not properly programmed. Since a technology that can completely eliminate errors and rework in our manufacturing processes doesn’t yet exist, we need a solution that can help mitigate them.
That’s where Avantguard comes into play. Avantguard is not just a tool, but a solution that is ready to significantly reduce the occurrence of errors and downtime, thereby boosting productivity, efficiency, and lowering costs. Avantguard is developed with your operators in mind, ensuring they perform reliably throughout the entire build process.
Track, Repair, and Recover with Confidence
Avantguard is an error-proofing software solution that detects errors and visually guides operators through critical tasks, including the repair process. In this article, we will explore several ways in which Avantguard helps reduce rework, its associated costs to you, and improve your production processes, particularly in cases involving rework and repairs.
1. Visual operator guidance
Avantguard doesn't just guide your operators, it empowers them. When an operator is working on an application, Avantguard provides visual guidance to help them through the process. In this way, your operators will never forget assembly steps or their order. Furthermore, when an operator makes a mistake, the system alerts them in real-time and allows them to correct it before the product proceeds further through the manufacturing process. This enables you to stay productive, reduce costs associated with scrap and rework, and enhance operational efficiency.
2. Part verification and tool interlock
In addition to verifying that the process is completed correctly, Avantguard can also verify the components against specifications during manufacturing, as well as select the correct tool with the right program. All of this guarantees product quality and compliance, ensures reliable fastening processes, maintains tightening sequence integrity, and captures results for repair analysis.
3. Avantguard’s rework stations
Approximately 35% of errors come from rework. Avantguard is designed to help eliminate these errors in rework stations.
So far, we’ve discussed how Avantguard is a valuable asset on the line; however, it truly shines with its ability to assist in rework stations. Thanks to its ability to provide real-time feedback and verify parts and tools with the correct program, Avantguard makes for the perfect asset when dealing with rework and repairs. Your operators will have a complete overview of each product's status (OK/NOK) and on-screen guidance to help them identify and address NOK issues, thus minimizing downtime and errors with clear instructions and support.
Not only will your operators be able to quickly and easily identify and correct NOK products, but they will be able to do so relatively quickly. Once you configure a rework station with Avantguard, it helps you to resolve issues while maintaining takt time. This quick setup process ensures that you can start benefiting from Avantguard's features without significant downtime.
Reworking automated processes with accuracy
While Avantguard excels in supporting manual operations, its benefits are equally strong for automated production lines. As mentioned earlier, your automated production lines are only as effective as your programming, tooling, and dedication to product variants. When any of these are misaligned or not properly configured, even the most advanced automation can produce errors. In this case, Avantguard becomes an ideal partner, integrating seamlessly with your automated systems, acting as a backup for when the cell goes down. In this case, it will help guide operators, helping to catch errors in assembly conditions such as torque, tightening sequences, part verification, and tool interlock. This way, Avantguard can help identify and prevent errors in real time, and assist in the operating process, until your automation cell is repaired.
Furthermore, when rework is unavoidable, Avantguard supports operators at the station by providing step-by-step guidance tailored to the specific assembly process. This not only helps accelerate your recovery but also reduces downtime in your automated cells, ensuring consistent production while enhancing quality and traceability.
Step-by-step operator guidance, from assembly to rework stations
Today, solutions that provide process control can make a significant impact on your assembly. When your operators get the job done right the first time, you can better allocate your time, spending less time on rework and repairs in the long run.
With Avantguard, you can do just that, all while completing day-to-day tasks. By connecting to your shop floor devices, Avantguard ensures tools activate only when necessary and with the correct parameters. Additionally, it can deliver on-screen step-by-step instructions customized for different product variants and options.
Avantguard can also connect with Manufacturing Execution Systems (MES) and/or other quality systems that may already be in place to access assembly data and maintain traceability by recording results at every step. This information can then be used to generate product reports, identify areas for improvement, or assist operators in repairing faulty products. This seamless integration with MES not only enhances the functionality of Avantguard but also ensures that you have all the necessary data at your fingertips for continuous improvement.
Let Avantguard revolutionize your assembly operations
For all your process control needs, Avantguard is the software solution that can revolutionize your assembly. Whether you’re new to process control solutions or an avid user, our experts can help get you on the right track to ensuring efficiency and top-notch product quality.
Contact our experts today to significantly reduce your risk of errors and line stoppages.
