[Thailand / zero defective products] A trial monitor is wanted for a revolutionary system! No NG parts were produced in the process. Going beyond the common sense of 100% inspection!

(Left) Mr. Oishi, MD of Nano Seimitsu (Right) Mr. Fukusho who developed software as the main person

Even if we try to promote 100% automatic sorting, not all of them can be automated due to the current technical and cost aspects. Differences in inspection accuracy, such as 100 microns and 10 microns, are also a major obstacle to 100% sorting. If you are dealing with a lot of products with an outside diameter tolerance of 10 microns or less, it is not so easy to perform 100% sorting using a camera.

However, it is the fate of parts manufacturers that even one-in-a-million pieces of defective products (NG parts) cannot be outflow.

Then what should we do? How to stop the outflow of one-in-a-million pieces of defective products (zero PPM) without 100% automatic inspection?” The answer is "elimination of in-process defects."

However, as that cannot be done, therefore it has been said that a “100% automatic sorter is needed”. You might think the story does not make sense. But maybe there is an "in-process guarantee method" that can guarantee almost close to 100%. Isn't there a method to inspect with sampling, which has more reliable quality control to prevent the occurrence of defective products in advance? Is there a way to create a system that can monitor more mechanically and complete operations according to the rules? It was that timing when I was thinking about these ideas, that I encountered the president of Office H.F, Hiroo Fukusho

Software to eradicate in-process defects will become the standard for parts manufacturing!?

Mr. Fukusho, who is also an excellent system planner, spoke to me, "Is there anything I can do for you?" Therefore, I discussed the ideas that I was thinking about with the in-process monitoring management system, Mr. Fukusho offered full support, saying "This is interesting, let's do it."

After a lot of trial and error, we completed the system called "LINE QC SPECIALIST".

3 features of LINE QC SPECIALIST

① Cannot make abnormal products
② Cannot operate or do work out of the rules
③ If an abnormal product is about to be created, the monitoring software will prompt the machine to stop.

The specific contents are as follows.

・ Measurement instrument calibration management (calibration content, time) = Software intervention in measuring instrument reliability
・ Divide between adjustment and start of mass production = Systemize mass production approval
・ Divide between central control value setting during adjustment and control value setting during mass production = Focus on central control during adjustment
・ Convey the measurement location and measurement frequency to the operators and encourage them to measure the correct location with the correct control value.
・ If "measurement frequency cannot be observed", "measurement value has reached the control value", or "instrument calibration time has been exceeded", the software issues a warning

We are looking for a trial monitor for a new system that will reduce the process management effort!

Usually, in mass-produced parts, it is rare that a sudden defective product occurs. If it can be managed properly, it can be prevented. However, the patience and physical strength to continue and improve the process control is not easy. Have software take part of it. That is the aim of developing this LINE QC SPECIALSIT. If you are interested in LINE QC SPECIALSIT, please apply for "Trial Monitor" using the inquiry form below.

▲LINE QC staff visits the assigned manufacturing process facility with a mobile wagon and performs measurements at regular intervals


▲Measuring instrument that can send measurement data

▲Control chart and trend management display tablet

LINE QC