Automating in-process controls with accurate data collection
Statistical process control (SPC) is a fundamental methodology that allows companies to monitor production processes in real time, ensuring high-quality parts, predicting production progress and facilitating continuous improvement. The effectiveness of SPC, as recommended by the IATF 16949:2016 standard, depends on the use of statistically significant and reliable data. But experience tells us that the statistical value of a sample measurement is all the more significant the larger the volume of samples checked.
For this reason, Dimac's research and development department has worked hard over the last five years to produce automatic sample control solutions, meaning free from manual intervention (to eliminate human error) and equipped with mechanical feeding systems capable of speeding up processes. All directly on the shop floor, without the need for specialized operators and integrating the data collected into the company's ERP system for seamless process management.
Some application examples of these solutions are represented by the following marketed products:
SPC-360: robotic unit designed for the automation of sophisticated in-process controls on complex parts obtained by cold forging and secondary machining operations, offers statistical reporting and centralized data collection through automatic non-contact measurements and without human intervention. Surface inspection cameras with artificial intelligence capabilities can be included in the layout to detect small surface defects. The machine can also host Eddy current NDT stations for heat treatment control and crack detection.
SPC-EVO: automatic mobile unit designed for SPC inspection of flat parts such as washers, sealing rings and components produced in multiple shapes by fine blanking. Automatic measurement of multiple parts is fast and accurate, resulting in significant time savings.
SPC-EVO allows the inspection of small batches of 5 to 20 parts in a row, fed by interchangeable blisters filled offline. Dimensional control and surface inspection are performed on both faces of each part by two high-resolution digital cameras with bi-telecentric optics and collimated illuminators.
SPC-LAB: mobile unit designed specifically for SPC inspections of parts with cylindrical geometry, produced by cold forging or turning. SPC-LAB facilitates the production part approval process (PPAP) by measuring simple and complex geometries directly on the shop floor. No metrology rooms or technical skills are required. With a single click, all measurements are immediately available in the company ERP system, allowing any process deviations to be detected and corrective actions to be enabled, resulting in time savings.
The advantages of Dimac's automatic SPC solutions are:
• Real-time collection of accurate and reliable digital data directly from the production department.
• Integration of SPC data into the company's ERP system for better process management.
• Reduction of time required for SPC checks and data analysis.
• Elimination of human error;
• Instant information collection allows you to monitor and improve processes in real time
