For any team, good communication is paramount. It allows us to share knowledge with those who need it and attain information we haven’t personally experienced. The ability to communicate well also facilitates how we use manufacturing systems and machines, leading to proper methodologies, greater insight, smarter decisions, and faster performance.
But what if you could extend that level of communication directly to your systems and equipment, and enhance how the manufacturing team communicates with powerful worker-machine connectivity?
This level of communication is already here, enabling your tools, systems, and people to work as one cohesive team, providing fast and accurate actions across the manufacturing operation.
Do you know how it works?
VKS DataConnect: The Digital Middleman
DataConnect is a VKS feature that enables your digital work instructions to communicate with external databases in real time. These databases can then interact with physical systems, machines, and tools to create a strong and reliable digital thread.
In essence, worker-machine connectivity functions as a “digital middleman, sitting at the center of the manufacturing operation and facilitating the transference of information so that each system can record data and act accordingly.
This technology allows operators to automatically access, activate, retrieve, and initiate other systems and tools by solely interacting with their digital work instructions, greatly mitigating the back-and-forth many manufacturers have to put up with on a daily basis.
Worker-Machine Connectivity: Data Flows Up & Down the Digital Thread
With VKS DataConnect, information flows both ways through the connected system to ensure that all people and associated systems share the same information within the same digital thread.
VKS initiates the process by sending out parameters to a stored procedure on a database. The data within the database can be monitored by another system or tool, such as a PLC (Programmable Logic Controller), to activate other processes.
The stored procedure then replies with the requested data, enabling VKS to monitor and retrieve data from every worker-machine connection.
6 Ways You Can Leverage Worker-Machine Connectivity
Send Programs to Robot/Machine
Label Printing
Verify Tool Calibration
Vision System Integration
Receive & Store Data from Test Bench
Daily Rounds/Mobile Audit
1. Send Programs to Robot/Machine
VKS DataConnect enables your work instructions to receive data while also sending programs to activate external systems and tools. This worker-machine connectivity provides smart error-proofing as well as increased efficiency for the operator.
In many manufacturing environments, operators are required to interact with several tools and systems to accomplish their tasks. But what if the operator only had to look and interact with one screen?
VKS digital work instructions and DataConnect enable your workers to perform each of these functions while only interacting with one system. Once an operator has performed their work, VKS can autonomously initiate the functions and actions of other systems and tools.
For example, operators loading the jig of a welding robot simply need to follow their instructions in VKS, and the rest of the process is automated.
Here’s how it works:
- The operator places the components into the welding jig and then activates the DataConnect prompt.
- VKS sends the program number to an SQL database which is monitored by a PLC.
- The PLC detects the new line of data and transmits the robot program number to the welding robot while also receiving data from the robot’s proximity sensors.
- Proximity sensors confirm they are present and in the correct location.
- Pass: The welding robot performs the required welding while the operator loads the second jig.
- Fail: The operator confirms and repositions the failed part, retriggering DataConnect when ready.
2. Label Printing
When operators need to fill out a non-conformance form or print a label, it can often require the use of other systems or worse… writing it down on loose sheets of paper.
Using DataConnect, businesses can connect their work instructions with an external printing software to automatically print a label when the operator needs one.
By allowing VKS to communicate with the printing software, companies can ensure that the crucial data entered into their Smart Forms is exactly the same as what’s being printed on the label. This capability enables businesses to unite digital and physical processes with one simple solution, thereby enhancing process control. The operator only needs to enter the information once, ensuring that there is one strong source of data and zero deviations.
For example:
- An operator completes assembling a component and is now required to print a label with the corresponding information.
- The data that has been gathered throughout the process is transferred to the printing software.
- The printing software then relays the necessary information to the printer and the operator places the label on the part.
- VKS then receives either a Pass or a Fail and the corresponding actions are fulfilled.
This process can be used to visually identify product details, shipping information, non-conformance parts, and more.
3. Verify Tool Calibration
A key feature of VKS DataConnect is its ability to communicate with external databases. This communication manifests itself in a few key ways.
- Retrieve information from the database to accomplish specific actions.
- Verify data is accurate and up-to-date.
For example, imagine that you are assembling a control panel for freight locomotives. Because the parts will experience different stresses due to the movement of the train, you need to validate that your assembly tools have been recently calibrated.
If tools are not properly calibrated, registered torque values could veer away from the real-life applications of torque. For this reason, manufacturers need a way to connect with their tools and machines to ensure that they will work properly at every working moment.
In this situation, VKS DataConnect can quickly communicate with an external database to ascertain if the tool was recently calibrated. VKS confirms when the last recorded calibration was and communicates with the user on the next appropriate steps.
The scenario would follow like this:
- While following their work instructions, the guidebook prompts the operator to scan their tool before measuring a dimension.
- The operator scans the tool’s barcode into the VKS Smart Form.
- VKS communicates with a calibration database to verify if the tool was recently calibrated.
- VKS then receives either a Pass or a Fail and the corresponding actions are fulfilled.
- Pass: The form closes and VKS records the result. The user can begin measuring the critical dimension and VKS will automatically record the dimensions in the VKS Smart Form.
- Fail: VKS prevents the user from moving forward until they use a calibrated device or a supervisor authorizes them to proceed.
Additionally, VKS logs the calibration results and stores evidence of the validation, ensuring companies have a detailed record of actions on the shop floor.
4. Vision System Integration
Another method to enhance worker-machine connectivity is to activate various inspection tools directly from their work instructions.
For example, imagine a process where each assembled component needs to be inspected by a visual inspection system with an integrated camera. Once a piece is completed, the operator places the part within the inspection area and then initiates the inspection program through VKS.
Once the inspection has been activated, the operator can start the assembly of a new piece, streamlining the inspection process.
Here’s how the inspection process works:
- An operator is required to place their part in a jig and trigger the camera inspection.
- Once the component is in place, the operator activates DataConnect and VKS sends a stored procedure to an SQL database which is monitored by a PLC.
- The PLC detects the new line of data and transmits the inspection program number to the attached camera.
- The camera confirms all labels are in the correct position, rivets are installed, and more. VKS then receives either a Pass or a Fail and the corresponding actions are fulfilled.
- Pass: The part passes the inspection and can be packed and shipped.
- Fail: The part is automatically rejected in VKS and sent for repair.
Pro Tip: Any data collected by the visual inspection camera is automatically stored and users can find this data in VKS Reports.
5. Receive & Store Data from Test Bench
Similar to our last example, VKS DataConnect also enables users to connect and directly communicate with test benches while automatically storing the results.
With a direct line of communication between test benches and VKS, companies can ensure that their products fully pass the testing requirements before the next phase of assembly can continue.
For example:
- An operator is following a work instruction and he is required to install the circuit board into a test bench and validate its functionality.
- The guidebook prompts the operator to enter the work order and serial number of the circuit board within the VKS Smart Form to trigger DataConnect.
- VKS then receives either a Pass or a Fail and the corresponding actions are fulfilled.
- Pass: VKS records the result and allows the users to continue following the guidebook.
- Fail: VKS records the result in the report. Specific rules can be defined to block the user from continuing, guide the repair of the unit, rerun the test, send email notifications, display non-conformance report (NCR) smart forms, and more.
6. Daily Rounds/Mobile Audit
As modern manufacturing becomes increasingly complex, manufacturers need standardized methods that augment themselves and the systems around them to suit the precise needs of the production environment. At the same time, manufacturers need a method to inform workers of the precise changes that need to be executed.
So how do we accomplish this using worker-machine connectivity?
Using VKS DataConnect, operators can probe systems and machines to receive the exact information they need when they need it while also communicating with other databases to ascertain the best course of action. This capability enables manufacturers to have quick access to pertinent knowledge that fits the situation at hand.
For example, imagine you are performing daily rounds at a chemical processing plant and you need to perform 2 key duties.
Verify the key inspection points of a process manufacturing audit
Enact corrective actions based on the results of the inspection
By using VKS as a daily audit tool while connecting VKS to both the chemical vat’s sensors and an external chemical data table, workers can receive accurate directives as soon as the information is captured.
The scenario would follow like this:
- The operator performs daily rounds on a series of chemical vats, checking external and internal inspection points.
- The operator activates VKS DataConnect
- VKS communicates with the vat’s internal monitoring solution and validates conformance.
- VKS then receives either a Pass or a Fail and the corresponding actions are fulfilled.
- Pass: VKS will store the data and display that no further action is required.
- Fail: VKS records the result and communicates with an external data table to determine the best appropriate corrective action, such as adding specific quantities of materials, increasing temperature, etc. VKS then relays this information to the operator.
The Possibilities are Endless
While we’ve shown 6 separate examples of how VKS DataConnect can be used to facilitate worker-machine connectivity, the possibilities for streamlined connections on the shop floor are virtually endless.
By facilitating strong connections between the people, systems, machines, tools, and databases on your shop floor, manufacturing staples such as teamwork and informed decision-making become faster and more effective.
If you’d like to know more about how worker-machine connectivity can unite your operations and facilitate accurate communications, book a demo today.
