Challenge details:

At our plant, a continuous engine assembly line (with 40 assembly stations) handles various engine models, each undergoing multiple operations at designated stations. The inspection of the engines is deferred until all assembly steps are completed and rework is planned for the engines which have discrepancies.

It is expected that the missing or incomplete operations should be detected instantaneously, and an alert is issued to the operator so the same can be completed. In case of fastening (nut cranking) operations, it is necessary to record the torque values and link to respective engines for a later retrieval of these for tracking. This ensures precision in fastener application, critical for engine reliability and performance.