Operators need the correct supplies in order to build products and maintain a smooth workflow. Restocking assembly stations on-time, before components run out without overstocking and creating congestion at a station is a challenge. Real-time communication between assemblers and the forklift operators who stock their stations would enable more efficient delivery of components as well as the timely removal of completed products.
 
Increase production efficiency by developing a wireless call-for-parts, service, and Andon system that allows for up to 35 work stations to call out to 12 forklifts/Hi-Los using illuminated indicator lights on a wireless Direct Select operator interface. This provides for quicker responses from forklift drivers and/or supervisors to indicate a request has been accepted. When creating a call system using wireless indicators, work stations can maintain a steady workflow and resolve critical issues quickly. Total time of requests, number of requests, and total time to acknowledge requests are tracked, allowing analysis of average delivery and acknowledgement times for each station.
 
Each station has a single call with a lighted response that is initially red upon request and becomes yellow after it is acknowledged by the Direct Select. On the Direct Select, a display shows the station number that has requested a call and flashes an LED indicator to alert the mobile responder that assistance has been requested. Once a call is accepted and assigned to a mobile responder, other available responders will update the next station in the queue. This system provides the information necessary to react quickly to work station requests and drive efficiency improvements based on data that was previously unavailable.
 
Application: Provide a wireless call-for-parts, service, and Andon system
 
Challenges: Real-time communication between multiple workstations and forklifts/Hi-Los
 
Solution:Touch Buttons and Wireless Direct Select Operator Interfaces, often paired with a Wireless Controller (avaiable through our dedicated hardware bundles)
 
Benefits: High visibility LED indication for call and acknowledgement, dynamic queue with visual display at the forklift of which stations are calling, and reliable Sure Cross® wireless network enables communication between devices
Call for Parts, Call for Service, or Andon: 35 call stations fitted with Touch Button Nodes can have a single call for parts, call for service, andon, call for pallet pickup, etc. The system can be expanded to allow additional call stations as long as the total call station and mobile responder count does not exceed 47.
Call Response: 12 Direct Select Operator Interfaces can be used on mobile responders to accept calls as soon as they are available. The system can be expanded to allow additional mobile response devices as long as the total call station and mobile responder count does not exceed 47.
Event Counters: Automatically tracks the total number of calls made, calls completed, calls cancelled, and more.
Email Alerts: Uses Lean.IQ Cloud Data Services to generate email alerts if wait times are long or if there are too many stations in the queue.
Efficiency Metrics: Provides efficiency metrics, such as average call times, average wait times, and average times to acknowledge calls.
Remote Monitoring: Pushes data to CDS, customer-specific cloud servers, or PLC for remote viewing, generating alerts, and logging data.