Part Tracking

Scenario

  • The customer returned a part because it had malfunctioned.
  • The part has a number engraved.
  • The customer requested report (numbers) for the part.
  • QC people want all the numbers for all parts produced that week.
  • The part was made several months ago.
  • You had better days.

Step 1

For this we need part serialization. This means that each part ever made has to have a unique number assigned to it. In our case the engraved number is in the following format:

  • nnnn = part number for the day
  • ddd = Julian day
  • yy = last two digits of the year
  • s = shift

Step 2

The Excel program has a ‘Decode Engraving’ feature, which is actually a database search by an engraved number. We type the number into the form. As we type the number is decoded into year, month, day, etc.Based on this a file name which contains the part data is constructed.
tracking 1

Step 3

By clicking on the file name the file is opened and the particular part data is displayed in the ‘Form View’. This can now be printed, faxed or e-mailed.
tracking 2

Step 4

File names are coded as MachineNo_yyyy_mm_dd.txt where:

  • MachineNo = machine number
  • yyyy = year
  • mm = month
  • dd = day
  • .txt = file format is a plain text file

From this and the calendar we can find all the files that QC people need.

Reject Report

Number of rejects per a station or reject code. A reject code is assigned to each operation. The sheet summarizes rejects per an operation and the part style. The ‘I’ column shows percentage of total rejects.

Reject 2

The same sheet (report) contains an ordered list of 10 most frequently rejected pallets (fixtures). A worn-out fixture may cause of lots of grief. This allows us to quickly estimate if something is out of ordinary.

Reject 5

Rejects vs Pallet Number

five stars
Sometimes this feature itself may pay the whole system off. Check out the example in our case study. This works equally well for both, palletized systems and index tables.

Reject chart shows number of rejects for a specific pallet (fixture). This can be shown for total, or per reject code (operation).
Reject 3

By selecting a reject code the chart shows number of times a pallet was rejected on a specific operation – station.
Reject 4