Aegis Software

Speaker:
Aegis_Bild_Dr. Nolting1Dr.-Ing. Friedrich W. Nolting is shareholder of Aegis Software GmbH in Erlangen. He achieved interbranch recognition by numerous developments for the Electronic Industry. Today his concepts and designs for e.g. setup optimizations by using the cluster method or the dynamic recipe optimization for LED binning are used by many vendors
Contact:
Aegis Software GmbH
Wetterkreuz 27
91058 Erlangen
Germany
+49 9131 7778 12 (office)
+49 172 83 92 764  (mobile)
+49 9131 7778 88 (fax)
fnolting@aiscorp.com
www.aiscorp.com/de
Abstract
Topics:
Controlled Process flow even for small lot sizes – How could the NPI team meet these challenges?!
Agenda:
Small lot sizes and high product mix require adapted work- and process flows including instructions and route control
NPI Team work support
Examples of work instruction templates
Case Study and Results
Advertorial
Controlled process flow even for small lot sizes – how can the NPI team meet these challenges?! Dr.-Ing. Friedrich W. Nolting
Summary
The only way to achieve a truly flexible manufacturing environment is through complete digital data management of design data, revision control, work instructions, bill of materials and shipping, whilst also monitoring revisions and technical adjustments. It’s also a solution during planning, that leads to quality improvements, reduces engineering and management overheads and achieves reliable repeatable manufacturing processes. Only a holistic data- & document-management approach, including version control and change management will achieve all these benefits.
Requirements for work-flow preparation
This is all about the delivery of information, or data, and in a paperless environment that is delivered digitally. But we need to consider more than just the method of delivery, we need to envisage the type of data, the interactivity of that data, its revision control and its adaptability.
When a truly paperless system is put in place that addresses all of these issues the benefits can be substantial. When documents are merely replaced with a digital version, the benefits are much more limited.
Take for example cost. Top of the agenda for many companies, particularly those that find themselves in the competitive space that is the EMS (Electronics Manufacturing Services) industry, where quarterly calls for cost reduction from OEMs (Original Equipment Manufacturers) are commonplace. In a paperless environment customer audits, quality audits and regulatory audits can all be done via a digital terminal and via a single system, with all revision control and document management visible. This could even be done remotely in some cases further reducing costs.
This is potentially a cost saving for the vendor but also for the customer, something that they will doubtless appreciate and remember. Another cost benefit comes in the form of reduced, or even eliminated personnel costs associated with the maintenance of documents like standard practice manuals, preventative maintenance manuals, user manuals and work instructions, all of which can be managed centrally rather than being disbursed all over the shop floor.
And the obvious cost saving of any paperless system is paper and the costs associated with printing and distributing that paper around the shop floor. It’s not like the work instructions are static. They change constantly and in a paper driven world that means reprinting numerous versions, distributing them around the shop floor, making sure everyone has seen them and doesn’t use old instructions. This is time consuming and risky.
And risk reduction is the second benefit worth highlighting in the paperless environment. The potential presence of down-revision documents on the shop floor is eliminated in a well-ordered paperless system; audits become risk free and operators are not in danger of building to the wrong document, which could lead to costly rework and/or scrapped assemblies.
Beyond reduction of cost and risk, there are the improvements in performance and quality to consider. Optimizing the performance of an operator is about having them spend as much time as possible making, testing and shipping product, not searching for or through documents to find an instruction or procedure. In a CAD (Computer Aided Design) driven paperless environment test and diagnostic data can accelerate the resolution of quality issues or the data required to expedite a repair function.
A paperless system also allows the operator to become part of the process improvement feedback loop. Feedback systems allow for fast and effective improvements in the documentation and more importantly in the process and multiple operators on multiple lines and/or shifts can impact upon any improvement initiative.
Paperless processes also provide interactive visual data that can guarantee the current and proper parts list and CAD information is available improving quality, increasing inspections reliability as well as raising the accuracy of diagnostics and repair.
The path to truly flexible manufacturing environment
The path to success requires a holistic approach that fully embraces many factors. As mentioned before digital delivery is fundamental and this needs to be available to each operator on his or her own terminal. The shop floor portals should be capable of presenting interactive operator visuals, CAD and BOM (Bill of Materials) information, revision control data, analytics regarding processes, as well as supporting secondary, less regularly used documents like preventative maintenance or user manuals or standard practice manuals.
All of these documents need to be more than just flat representations. They need to be interactive allowing data to be visually queried by the operator via a simple user interface that allows for a deeper dive into data by simply clicking or touching the item in question. Visual documents that are grounded in both the CAD and the BOM and that are interactive can be queried for rich, always current data that refers back to the central manufacturing database. The final part of the interactivity puzzle is the ability of the operator to redline and provide improvement feedback.
Revision control is a cornerstone of any system, be it with or without paper. The system must control and be fully aware of process version, design version and the stations where documents are to be deployed. The paperless system should be capable of automatically ensuring that the right documents and analytics are presented to an operator in a single scan with zero risk of displaying the wrong revision of any data.
No system can work without a degree of built-in flexibility or adaptability. The system will need to allow engineers to ‘cut in’ an emergency engineering change or a process change if it is required on the shop floor. This will need to occur digitally, simply and seamlessly, with the proper documentation and recording procedure supporting it.
The results speak for themselves
The positive results of such an endeavour speak for themselves and can be seen from the experiences of all those vested in the process.
From the operators’ point of view, they can bring up the correct revision assembly instructions, dynamic video assistance, CAD images, BOM information and all associated documentation and work instructions with a single scan of the unit in production. This can be done immediately and at any point in the manufacturing process. The operator also enjoys the ability to interrogate the data provided, rotating or zooming into CAD data or digging deeper into a BOM to query a particular part. First article assembly and inspection become simpler as the operator can receive adapted and dynamic information. And finally the operator can close the feedback loop by sending suggestions to the engineering team from their own terminal instantly, supporting their value and the continuous improvement of the product and process. There is plenty of evidence supporting the tenant that operator satisfaction is much higher when the data provided to do their job is unambiguous and when their voice is heard. All lean manufacturing principles completely support the concept of operator involvement and the paperless environment simplifies this process.
New product introduction becomes faster, simpler and more reliable with a paperless system. Digital review and approval procedures, using electronic signatures, are simplified and are more reliable, ensuring that improper data never reaches the shop floor, and traceability is absolute in all product documentation and data.
The only way to achieve a truly flexible manufacturing environment is through complete digital data management of design data, revision control, work instructions, bill of materials and shipping, whilst also monitoring revisions and technical adjustments. It’s also a solution during planning, that leads to quality improvements, reduces engineering and management overheads and achieves reliable repeatable manufacturing processes. Only a holistic data- & document-management approach, including version control and change management will achieve all these benefits.
Aegis Repair Station

Aegis Repair Station

NPI Engineering workflows and tasks

NPI Engineering workflows and tasks

Company Profile
Aegis Software is the leading provider of innovative software solutions to improve speed, control and visibility throughout manufacturing operations.
Founded in 1997 by two manufacturing engineers, Aegis has over 17 years of experience providing world-class software to customers around the globe. Our install base spans more than 1700 factory sites across the electronics, medical, automotive, military and aerospace industries.
Aegis is your turn-key solution provider with direct staff and operations in China, Germany, Japan, UK and the US. Our organization develops, deploys and supports our solutions in-house, eliminating third-parties and providing customers with faster support and a better solution, in less time and at a lower cost.
For over a decade, Aegis has maintained more resale and technology integration partnerships with leading machine vendors than any other software provider. Today Aegis is partner to 36 machine vendors. These partnerships provide customers the best offline programming and real-time data acquisition systems possible.