TUBE WELDING

Monitoring and traceability reporting of the tube manufacturing process

THE NEED _

The manufacturing of precision welded tubes for various components in the automotive market requires production monitoring and exhaustive process data analysis to meet the required quality standards.

Our client manufactures welded steel tubes for this sector in a continuous welding facility. The main needs are the monitoring of process parameters compared to the reference values in manufacturing orders, and the reduction of time and effort in preparing forensic analysis reports when quality complaints arise from the end customer. Currently, it is necessary to use multiple information systems and data sources to prepare a comprehensive product traceability report that clearly and in detail reflects the material used in the production of the final product, as well as the parameters used in the manufacturing process.

THE ADVANTAGES _

Reduction of time and effort in preparing forensic reports

Quality of the information presented in the reports and direct online access to the reports by the entire organization

Generation of a database open to other uses such as training machine learning models to improve process efficiency

24/7 monitoring of operating parameters and reducing response time to incidents

THE SOLUTION _

An adaptation of our MONITORING application was carried out to visualize process parameters and an integration of data sources for the analysis of process traceability through our TRACKING application. Additionally, the RESTAPI application was developed, through which data is transferred from ii40 Connect to external API servers for the generation of statistical process control (SPC) reports that are sent via email.

MONITORING _

COCKPIT

The RT control panel has been customized to display relevant process parameters. Data displays have been designed to compare reference values from manufacturing orders with actual process parameters collected at the machine. Temperature, operating pressure, welding current, and frequency are monitored, among other parameters, and the real-time data is compared with the data from the current manufacturing order.

ALARMS

Alarm log panel for process parameter variation and out-of-range values. Real-time incident detection emails. Customer-configurable alarm engine based on process variables.

ANALYSIS CHART

Temporary graphical display of parameter readings. Ability to configure quick preset buttons to group parameters according to data analysis needs.

TRACKING _

ORDER TRACKING

From an information request screen, select a time window to request information about manufacturing orders between dates. This query returns information about the orders manufactured in the time window, as well as the materials used for their manufacture and process parameters. It also includes information about the finished product and links the manufacturing orders to the finished product, raw materials, and process conditions, such as machine parameters or the chemical composition of the materials used.

This traceability report can be downloaded in a detailed and clear report that displays all the information related to a manufacturing order.

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