Minimizing machine downtime and maximizing performance during production are the two essential factors for optimizing output. Minimizing downtime starts from job preparation and production planning, i.e. even before a production job is sent to the machine:

• Make sure that the materials needed for the job are available at the machine in time (wires, tools, terminals, seals, etc.). Even with accelerated production, it is difficult to make up for time lost due to missing materials.
• Send production jobs in the correct orientation so that the operator does not have to turn the article first.
• If a material change is unavoidable, send the jobs in the right order and orientation to minimize the materials that need to be loaded on and set up again.
• Bundle production jobs with the same material. This avoids the need for material verification unless it is mandatory for quality assurance reasons.
• After the first job, skip process verifications for multiple jobs with the same materials unless they are mandatory for quality assurance reasons.
• Use the autostart function for multiple consecutive jobs with the same materials when verifications are not mandatory. This means that subsequent jobs are executed directly one after the other without an explicit start command.
• If your article requires different processes for both ends, set up the more time-consuming processing on side 2 if possible. This allows you to make optimum use of processing and transport in parallel, saving valuable time.
• If more processing errors and rejects are expected in a given process, set up this process on side 1. This will mean that only one lead end is lost in the event of a processing error. The material rejects and time lost are significantly reduced. 
• Komax HMI informs you about the full machine configuration, all process parameters, and the articles currently loaded onto the machine. If your manufacturing execution system (MES) supports the MIKO interface, use this information to send the follow-up jobs in such a way that only minimal changeovers are necessary.
• Optimize batch sizes and sequences so that the machine does not have to wait for the operator, for example because they are carrying out administrative work or checks, or operating other machines. If possible, make sure that the operator is ready for the manual operations as soon as the machine presents a finished batch in the tray.

Ensure quality, disable unnecessary checks

In most cases, the quality specifications set clear requirements. With Komax HMI, these requirements are already defined in the article definition when creating the specification for the corresponding parts and monitoring. Activate only the checks that are really necessary, because quality checks always cost a few milliseconds of process time.

• Ensure that the quality specifications and tolerances specified for the article meet the basic requirements. Use the machine’s numerous quality monitoring functions to assure quality compliance, e.g. automatic conductor detector (ACD), Q1240 and Q1250 optical monitoring for analyzing stripping and seal position, CFA or CFA+ Crimp Force Analyzer, etc. Deactivate all non-essential quality checks if no particular specifications apply. Each monitoring process takes fractions of a second for testing and data processing. 
• Observe the quality settings in the WPCS Converter. They are used to ensure compatibility with TopWin and automatically apply to every job via WPCS. Make sure that the set quality checks meet the requirements.
• If you monitor the seal position with a Q1240 or Q1250 optical monitoring system, you do not need an additional seal presence analysis, because the position monitoring system automatically detects missing seals.
• Disable terminal presence monitoring when using CFA or CFA+. For this quality check each terminal travels an additional distance, which costs valuable time. With the CFA or CFA+ Crimp Force Analyzer, the machine also reliably detects missing terminals and reports the corresponding processing error.

Optimize process flow, activate only necessary functions

Once the job has arrived on the machine, the process must be set up. By choosing the process parameters, the process engineer and operator can significantly influence machine performance: 

• Accelerate the swivel arm as much as the process and article will allow. In most cases, you can leave the preset maximum values. If necessary, the easiest way to reduce acceleration overall is to use the horizontal acceleration correction control, even during production. This is especially true for heavy terminals, very thin and flexible wires, and quality-critical articles.
• Shorten process waiting times as much as the process allows: waiting times during cutting, acceleration, after stripping, and during the seal process, and slow-motion seal separation, crimp speed, as well as speed, acceleration and waiting times during wire transport and deposit. Note that the speeds and accelerations for transport only have an effect on articles of medium length and longer.
• Use crimp process optimization and define suitable crimp stroke positions when the wire has reached the process position or moves away again. This starts the crimping process even before the wire has reached the final crimp position.
• Activate the special deposit functions only when they are really needed. This applies in particular to the deposit gripper and the deposit optimization (wire deflector). The same applies to the hold-up unit  of the cutting process on Side 2.
• Eliminate the cut pulled strands (CPS) process step when using optical monitoring with the Q1240 or Q1250 system. With CPS, an additional cut is made for each wire cut, whether it is necessary or not. This additional cut costs valuable time. If you use optical monitoring, any pulled strands will be reliably detected as processing errors. 
• Use the special seal process before stripping only if absolutely necessary. The additional travel distances cost valuable processing time.

Set up process carefully, avoid rejects

When the job is finally produced, the aim is to avoid rejects. Rejects not only mean lost materials and the associated costs, but also add time spent producing parts to replace the rejects. Every one percent of rejects has the same effect as a corresponding drop in performance. The operator can significantly influence this.

• Processing errors and rejects are often the result of a process not having been set up optimally. You should therefore ensure that the operator sets up the process accurately. It is recommended to provide specific training on the process setup.

Regular maintenance for optimal performance

 The condition of the tools and the choice of raw materials have a direct influence on process stability and the reject rate. This in turn has an impact on output. The maintenance technician’s work should therefore not be underestimated. Saving on maintenance is a false economy.

• Worn tools cause process variations that easily lead to processing errors and rejects for quality reasons. This applies to crimp tools as well as cutting blades, drive belts, and other parts. If possible, ensure that the tools and wear parts are in good condition.
• Maintain and clean the machine and tools regularly. This not only helps you avoid process instabilities, but also unplanned downtimes that often occur at the most inopportune times.
• The quality of the processed material also affects the reject rate: if the quality of the raw material is inconsistent, processing variations can occur that exceed the quality monitoring tolerances and ultimately lead to rejects.

Pro tips: functions that make Komax HMI unique

Komax HMI offers you further optimization options – depending on the configuration of your machine and the options of your MES.

• Whenever possible, operate Komax HMI while production is running. You can adjust the priorities of jobs in the list or define articles even before the current job is finished.
• Track the quality results while production is still running, without having to stop the machine. This allows you to monitor critical processes live and react immediately if required.
• Use Workflow Tasks when the operator needs to perform additional tasks in the work process. With this function, these tasks become mandatory for starting production. This guarantees that the tasks will be carried out (and logged).
• Use the Q1250 optical quality monitoring for the process setup, too. Produce a process sample and have it evaluated by the Q1250. It will show you a photo of the sample and display the target values for the stripping length and the terminal position. This allows you to make corrections directly on the screen. To assess the position in the crimp tool, there is no need to pick up the samples or open the machine. 
• Define the user permissions for each operating element in Komax HMI so that the critical settings can no longer be changed. With Komax HMI, you can call up permissions via MIKO or define them differently according to the operator’s level of training – if required, you can even do this on a job-by-job basis, depending on the article and material. Please contact us for support with this.
• Once your process is optimized, you can record all the parameters with Komax HMI like a recipe and send them to the machine through the network (via MIKO interface) depending on the job, material or other criteria, so that the process always meets your specifications. Please contact us for support with this.

Customer-oriented solutions from the market leader 

Globally unique innovations like Komax HMI have a system. As a market leader and innovation driver, we develop our solutions in close cooperation with customers according to their current and future needs. This new operating philosophy is a further consistent step away from complexity to maximum simplicity.

> For more information visit the Komax website