Software for industrial automation

Sytec Group’s software controls the workflow of the entire assembly line and Quality Gates. It allows the product to be managed within the production process, identifying it, determining if it is in a condition that allows testing, and evaluating if it can proceed to subsequent stages. The testers are integrated into a line context, where each test can only be performed if the product has completed all upstream processing stages. At the line’s exit, the product validation function includes a cross-check based on the results of all tests performed, determining its compliance for use.

A sequence of fully configurable checks allows for automatic production interruption in case of excessive rejects or dangerous dimensional drifts. The goal is to minimize the intervention time between production and dimensional verification.

Each step in the assembly chain can be equipped, according to customer needs, with simple movement control systems or interfaces. The interfaces allow the insertion and/or modification of the parameters being measured.

Every component used in the assembly of the finished product can be traced, either based on the supplier’s production batch or uniquely, through a unique code assigned to the component (Serial Number).

Sytec Group’s software solutions interact with the company’s PLC and ERP/MES systems to achieve complete integration between the production and management departments, aiming to meet common goals in terms of production efficiency, cost control, inventory management, etc.

Sytec Group’s software includes a functional testing system with a fully configurable sequence of tests that can be associated with each finished product. The testing sequence is a combination of more or less objective physical measurements depending on the complexity of the measurement. The values measured must fall within a range or “recipe” that can be rigid (predetermined) or configurable. Any product that does not pass the required tests must go through the repair station, where the operator records the operations performed with a simple interface based on barcode reading defined by quality control.

The system can also include an “Andon” system; the Andon board is a key component of the quality control system according to the autonomation concept. The operator can stop production when a defect is found, to immediately request assistance. Common reasons for manual Andon activation are component depletion, a defect created or detected, equipment malfunction, or a safety issue. Work is halted until a solution is found.

Equipment control operations using Golden Samples required periodically by the system are performed automatically; only passing this test ensures the proper functioning of the equipment in production. Thanks to differentiated user profiles, the same interface can also be used for the periodic calibration procedures of measurement rings.

The system is completed by an intuitive machine diagnostics system, as well as a manual movement page for each system element for maintenance activities.

The system allows configuring a sequence of steps that simulate the final customer’s operation, specifying forces involved, actions to be performed, sampling frequencies, and whatever else the system provides. The bench will interrupt the test as soon as the conditions are not met or continue until all required actions are completed. At any time, the designated personnel can analyze and export the data acquired during the test directly from their PC.

All measurements collected and the resulting GOOD/FAIL evaluations are stored in a relational database and associated with the individual product’s Serial Number.

The system allows access to data within the company network to examine the collected values for statistical purposes or any “a posteriori” or “real-time” control of the tests performed. If the SPC analysis software is present, the data collected on the server system is transmitted at predefined intervals to the company’s information systems.