Patrick Britschgi, why are such companies often located in Eastern and Southern Europe?

Automotive manufacturers are fully committed to security of supply and quality at a European level. Their suppliers must deliver this quality without compromise. Their dedicated and experienced employees usually work in one or two shifts and process orders for around 100 to 10,000 units per job.

Are the higher wage costs not a challenge, compared to production in other regions of the world?

Of course. This is why these companies rely on a high degree of automation. Our machines are ideally suited for this, as they guarantee flexibility and investment security at the same time.

What are the automotive manufacturers’ quality requirements?

Car manufacturers demand uncompromising compliance with their product specifications and quality standards and want these to be documented. They often only approve processing procedures for their suppliers after painstaking testing. Furthermore, they want to know what their suppliers are doing to ensure reproducible quality. The Komax HMI operating software offers enormous advantages for all of this.

What are the effects of these advantages?

Komax HMI takes quality monitoring one step further than with TopWin by recording the complete crimp force curve for each individual operation. Komax HMI also records the images of the optical quality monitoring (i.e. the positions of the terminal and seal), compares the images with the required dimensions and saves them for full traceability. The optical quality monitoring also detects crimped-on strands and automatically sorts out the affected leadsets as unacceptable. Our customers can rely on the machine and its uncompromising focus on product quality, which is one of the great strengths of Komax HMI.

Do experienced employees really need the step-by-step guided workflow of Komax HMI?

Yes. To save on costs, employees often have to operate several machines at the same time, running different jobs with different requirements. To make sure each step is correctly followed for each job, it is very helpful if the system thinks along with you.

Are these processes not always the same?

The basic sequence of the steps in a manufacturing process – process setup, quality verification, production – is logical and efficient and therefore predefined. But OEMs often require additional process steps in the workflow, such as additional samples or quality verifications before and after production. Komax HMI can be configured so that these additional steps are included in the workflow and must be carried out.

What does this mean for the quality of the processed wires?

Process compliance is essential to ensure the required quality: The guided step-by-step sequence guarantees that the operator always adheres to the specified process and never forgets a step, even in hectic situations. Beyond that, each process step is automatically logged and can be verified to the OEM if required.

Is the processing procedure in Komax HMI always the same for all jobs?

Not necessarily. For example, material verification may only be requested for those jobs where the OEM explicitly requires this. Thanks to its flexibility for adjustments, Komax HMI can optimally support the requirements of suppliers and their customers.

Does the supplier also have a direct financial benefit from the guided workflow?

Yes, by avoiding inefficiencies. Because the company can avoid misunderstandings, there is no risk of inadequate quality, waste and additional costs due to an unaccepted job.

Do such companies also benefit from the new Machine Dashboard?

Yes, let me give you an example: Especially for more sophisticated articles, it is advantageous if the operator can follow certain process parameters and quality values in real time and permanently on the user interface – the Machine Dashboard. The operator can then react immediately in the event of any deviation.

Does the Machine Dashboard also need to be used when companies work with a production management system (MES)?

Today’s MES are usually not designed for controlling the production in real-time, nor do they have direct access to the latest process details. Typically, they only receive key production feedback after the job has been completed – too late for process monitoring. In addition, an MES does not display the information in the operating software, but often at a remote location from the operator. For this reason, process details must be displayed directly on the machine, in Komax HMI and on the Machine Dashboard.

The quality is undisputedly important, but can Komax HMI also increase the efficiency of a system?

Thanks to the guided step-by-step workflow, Komax HMI helps the operator to proceed efficiently and avoid errors. The new MIKO interface also allows for real-time network access to all machine data. This includes not only part and article specifications or job details, but also the machine configuration, machine settings, additional steps in the workflow and user permissions. This means that an MES can access nearly all the machine's production parameters and read them from the machine or specify them via network. So the MES has the information and the controls available to reduce the potential of errors, waste and unnecessary costs.

How does the MIKO interface contribute to increasing efficiency?

The MIKO interface is the optimal basis for active production controlling and quality monitoring, as well as for efficiency analyses with Komax Connect. With this convenient solution, the productivity and availability of the machines, the material consumption, the type and frequency of errors and other parameters can be analyzed, from which measures can be derived. For example, one of our customers managed to increase the production efficiency significantly by locating a material problem with Komax Connect – and then eliminating it.

Does MIKO also guarantee protection of the investment?

Yes, MIKO relies on common standards and paradigms to make the customer well-equipped for the requirements of the future. At the same time, Komax HMI also supports the previous WPCS interface for networking with an existing MES.

What should our customer do to integrate Komax HMI in their production environment?

I recommend that they gain experience with Komax HMI as early as possible. The local Komax representative will support them with the order, installation and operation. If these experiences result in further requirements, Komax will work with the customer to jointly specify the solution and customize Komax HMI accordingly.

Komax HMI