Error Proofing and Andon Solutions Help Automotive Manufacturers Increase Efficiency and Improve Production Quality


MILWAUKEE— Rockwell Automation today announced the availability of two lean manufacturing solutions designed to help automotive industry manufacturers improve the accuracy and efficiency of production and assembly line processes — ultimately helping minimize waste, increase product quality and optimize the use of parts and labor.

The new Rockwell Automation Error Proofing and Andon solutions leverage the company’s automotive industry expertise, FactoryTalk integrated production and performance software suite, and Logix Control Platform to help automotive manufacturers seamlessly share manufacturing data with business level systems. By capturing real-time plant-floor data such as installed part or downtime information, the Error Proofing and Andon solutions can help manufacturers maintain product quality andprovide the flexibility to make equipment changes as necessary to help reduce engineering costs, enhance operational efficiency and manage total cost of ownership.

“The key factor driving the automotive industry today is the need for better information flow between the plant floor, enterprise systems and the external supply chain,” said Jim Neawedde, segment business lead, Rockwell Automation. “Not only do the Error Proofing and Andon solutions allow manufacturers to quickly identify and respond to challenges in their production environment, they also support their lean manufacturing initiatives.”

The Error Proofing solution is built using preconfigured modular templates within FactoryTalk View, FactoryTalk ProductionCentre and FactoryTalk Integrator to provide manufacturers with an automated process that interfaces directly with the assembly line. The templates provide work instruction displays, part verification and automatic tool control to guide operators through each step in the production process. This helps improve product quality and ensures that operations are completed in the correct order using the appropriate parameters, and within the allocated time.

Within an operation, Error Proofing immediately verifies that the proper parts and tools are used and procedures and specifications are followed, otherwise work is stopped until corrections are made. All of this minimizes mistakes and drives defects out of processes to ensure that the product has been correctly built. As a result, manufacturers can operate at a consistent level of quality and profitability while meeting each customer’s unique requirements.

The Andon solution leverages FactoryTalk Metrics, FactoryTalk ProductionCentre and FactoryTalk Integrator with the information-enabled Logix Control Platform to help manufacturers capture real-time event information, identify production problems and more efficiently adjust operations to minimize errors and reduce downtime. The Andon solution leverages line side displays, stack lights and pull chords, and a variety of other electronic devices to display the real-time work status and production problems for operators and manufacturing personnel. Immediate access to this information helps manufacturers reduce the occurrence of costly mistakes.

As part of each offering, Rockwell Automation engineers work with automotive manufacturers to assess their application needs and customize an Andon and/or Error Proofing solution based on their specific needs. Combined, the solutions help automotive manufacturers more rapidly respond to challenges in their production environment and facilitate an immediate critical response to assembly or workflow problems.

Rockwell Automation, Inc. (NYSE: ROK), is a leading global provider of industrial automation control and information solutions that help manufacturers achieve a competitive advantage in their businesses. The company brings together leading global brands in industrial automation which include Allen-Bradley® controls and services and Rockwell Software® factory management software. Headquartered in Milwaukee, Wis., the company employs about 19,000 people serving customers in more than 80 countries.
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