Truck & Off-Highway Engineering - February 2018 - 6

TECHNICAL INNOVATIONS

4.0 insight not only
catches defects as
they occur on the
line, but also can
spotlight emerging
trends and patterns
before they become
a production issue,
says Sciemetric's
Dave Mannila.

Collect the right data

A common starting point to achieve this
level of connectivity is to incorporate
in-process testing (IPT) into the production line. With IPT, measurement, monitoring, data collection and reporting is
built into each step of the manufacturing process. This provides intelligent
monitoring and pass/fail determination
6 February 2018

An example of the drill-down
capability to individual serial
numbers.

at the source, as well as acquisition of
the data that charts what happened to
each part throughout a process.
The result is a consolidated birth history record, indexed by serial number,
for every single part. This record includes all the data captured from each
process and IPT station on the line that
touched a part-captured at the point
of its highest fidelity and quality. This
data includes scalars, digital process
signatures and even machine vision images with their datasets.
It doesn't matter if that process is a
press fit, a weld, a rundown operation,
or dispensing a bead of sealant or adhesive-there is a place where a sensor
can be added and data collected into a
central repository. With this approach,
data silos are eliminated.
With today's intelligent data analysis
and visualization tools, the data contained in a birth history record can then
be mined at any time for insight. From
leaky seals and valves, to bad welds
and cracked castings, a problem can be
spotted and its root cause determined

with data-driven diagnostics and thorough reporting.
This 4.0 insight can be used for much
more than catching defects as they occur on the line. It can also spotlight
emerging trends and patterns before
they become a production issue that
leads to higher scrap and rework rates.
A growing number of OEMs, including
off-highway, have come to appreciate the
value of squeezing all they can out of their
technology and their data. To maintain a
competitive edge in a Manufacturing 4.0
world, companies need the ability to pluck
a needle from the haystack, at any time,
on demand, and scrutinize its every detail.
IPT and today's data management and
analysis tools offer a relatively easy starting point to boost the intelligence of manufacturing plants.
Dave Mannila, a senior product manager at
Sciemetric Instruments, wrote this article
for Truck & Off-Highway Engineering. He
has broad responsibility for new product
concept, definition and development, as
well as maintaining the company's overall
product roadmap.

TRUCK & OFF-HIGHWAY ENGINEERING

ALL IMAGES: SCIEMETRIC

test cells would end up in one silo, entered manually and indexed by time and
date stamp. Further up the line, some
process stations, such as torqueing for
bolts, collected full process signatures,
indexed by serial number, but this data
ended up trapped in a different silo.
When a product came back from the
field due to a customer complaint or
warranty issue, it routinely took as long
as a week to retrieve all the related scalar and process signature data scattered
across the plant.
This lengthy feedback loop created
uncertainty and long production delays-the manufacturer didn't want to
risk shipping defective products that
would tarnish its brand in the marketplace. In one instance, full production
was halted for several weeks.
For an investment that cost only a
fraction of a day of lost production, this
manufacturer standardized and centralized data collection and reporting
across the plant. Quality engineers now
had all the data they needed at their
fingertips, to catch defects in real-time,
trace root cause, and limit the scope of
a recall to the specific units the data
trail told them were suspect.

A unified reporting
environment, or dashboard,
provides production
managers with a high-level
view of manufacturing
metrics drawn from the data
being collected from the line,
along with the ability to drill
down to individual parts by
serial number.



Truck & Off-Highway Engineering - February 2018

Table of Contents for the Digital Edition of Truck & Off-Highway Engineering - February 2018

Truck & Off-Highway Engineering - February 2018
Contents
Editorial
Technical Innovations
Komatsu building AI into construction sites
Gaining the Manufacturing 4.0 advantage with data-driven in-process testing
Paccar reveals new and future tech at CES 2018
ChemSEI-Linker extends lithium battery life, increases EV range
Powertrain mix for CVs in Europe set to diversify, but cost is critical
Electrification not a one-sizefits- all solution
SuperTruck redux
From research to reality
Big Data a focus for 2018 SAE President Mircea Gradu
Original Equipment
Toyota unveils autonomous e-commerce concept vehicle, development alliance
Product Briefs
Companies Mentioned, Upcoming, Ad Index
Q&A
Truck & Off-Highway Engineering - February 2018 - Intro
Truck & Off-Highway Engineering - February 2018 - Truck & Off-Highway Engineering - February 2018
Truck & Off-Highway Engineering - February 2018 - Cover2
Truck & Off-Highway Engineering - February 2018 - Contents
Truck & Off-Highway Engineering - February 2018 - Editorial
Truck & Off-Highway Engineering - February 2018 - 3
Truck & Off-Highway Engineering - February 2018 - Komatsu building AI into construction sites
Truck & Off-Highway Engineering - February 2018 - Gaining the Manufacturing 4.0 advantage with data-driven in-process testing
Truck & Off-Highway Engineering - February 2018 - 6
Truck & Off-Highway Engineering - February 2018 - Paccar reveals new and future tech at CES 2018
Truck & Off-Highway Engineering - February 2018 - 8
Truck & Off-Highway Engineering - February 2018 - ChemSEI-Linker extends lithium battery life, increases EV range
Truck & Off-Highway Engineering - February 2018 - Powertrain mix for CVs in Europe set to diversify, but cost is critical
Truck & Off-Highway Engineering - February 2018 - 11
Truck & Off-Highway Engineering - February 2018 - Electrification not a one-sizefits- all solution
Truck & Off-Highway Engineering - February 2018 - 13
Truck & Off-Highway Engineering - February 2018 - 14
Truck & Off-Highway Engineering - February 2018 - 15
Truck & Off-Highway Engineering - February 2018 - 16
Truck & Off-Highway Engineering - February 2018 - 17
Truck & Off-Highway Engineering - February 2018 - 18
Truck & Off-Highway Engineering - February 2018 - 19
Truck & Off-Highway Engineering - February 2018 - SuperTruck redux
Truck & Off-Highway Engineering - February 2018 - 21
Truck & Off-Highway Engineering - February 2018 - 22
Truck & Off-Highway Engineering - February 2018 - 23
Truck & Off-Highway Engineering - February 2018 - 24
Truck & Off-Highway Engineering - February 2018 - 25
Truck & Off-Highway Engineering - February 2018 - 26
Truck & Off-Highway Engineering - February 2018 - From research to reality
Truck & Off-Highway Engineering - February 2018 - 28
Truck & Off-Highway Engineering - February 2018 - Big Data a focus for 2018 SAE President Mircea Gradu
Truck & Off-Highway Engineering - February 2018 - 30
Truck & Off-Highway Engineering - February 2018 - Toyota unveils autonomous e-commerce concept vehicle, development alliance
Truck & Off-Highway Engineering - February 2018 - 32
Truck & Off-Highway Engineering - February 2018 - Product Briefs
Truck & Off-Highway Engineering - February 2018 - 34
Truck & Off-Highway Engineering - February 2018 - Companies Mentioned, Upcoming, Ad Index
Truck & Off-Highway Engineering - February 2018 - Q&A
Truck & Off-Highway Engineering - February 2018 - Cover3
Truck & Off-Highway Engineering - February 2018 - Cover4
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