Industry

Production tracking and test data for appliance and electronics assembly lines

We combine data from assembly stations, end-of-line testers and poka-yoke checks under each product's serial number.

Let's talk about your project → What we deliver

Our clients

Siemens
Anadolu Isuzu
BSH
Tofaş
Toyotetsu
Martur
Turkcell
Vodafone
Doğadan
Pakmaya
Bross
Abdi İbrahim
Nobel İlaç
Plastimak
Dalgıç Kalıp
Barbaros Motor
Magneti Marelli
Rözmaş
Sanel

Appliance and electronics lines run at a high pace, and a delay at one station breaks the takt of the whole line. On the quality side, you must show that every unit passed end-of-line testing, received the right part and had its screws driven to the right torque.

VOLSOFT reads data from station PLCs, torque and screwdriving systems, barcode readers and end-of-line testers without touching control logic. Each record is tied to the product serial number and the work order.

Line balance, station-level downtime, test reject reasons and repair loops then show up in one data layer, and when a field failure comes back, the unit's assembly and test history is found by serial number. Every project runs on Proxus.

What we deliver

Appliances and electronics

Station-level takt and downtime

Cycle time, waiting and stoppages are measured for each station, so line imbalance and the bottleneck station are visible in the data.
End-of-line test records

Results and measured values from electrical safety, functional, leak and performance tests are stored with the serial number.
Poka-yoke and part verification

Critical parts scanned at the station are checked against the product's bill of materials, and a mismatch is shown as a warning at the station.
Torque and screwdriving data

Torque and angle values are read from screwdriving systems and written to the unit's record.
Repair loops and reject analysis

Repair actions on failed units and their retest results are tracked, and reject reasons are reported as a Pareto.

Processes we work on

Where the data starts in appliances and electronics

Assembly lines and stations
End-of-line functional and safety tests
Leak testing and refrigerant charging
Screwdriving and torque control
Poka-yoke and part verification
SMT and PCB assembly
Polyurethane foam injection
Sheet metal forming and painting
Packaging and palletizing

How a project runs

From discovery to live, step by step

01
Line and station analysis

Station PLCs, testers, screwdriving systems and barcode points are reviewed on site, and we map where the serial number is created and how it travels down the line.
02
Data model and pilot line

A shared data model for station, test and product records is built and put live on one line.
03
Tester and ERP integration

End-of-line test results are connected, along with ERP work orders, bills of materials and production confirmations.
04
Rollout and training

Further lines are added on the same model, and production, quality and process engineering teams are trained.

Built on Proxus

Proxus publishes station and tester data in a Unified Namespace organized by line, station and product, so MES, ERP and quality systems read from the same source.

Proxus is the industrial data platform built by the VOLSOFT team.

Proxus Unified Namespace ↗

Frequently asked questions

Common questions

How is serial number traceability achieved on an assembly line?

A serial number is assigned at the start of the line and read at every station, so each station's data is recorded against it. Critical part barcodes, torque values and test results are added to the same record. The unit's assembly and test history can then be queried by serial number.

Can data from end-of-line testers be collected?

Yes. Measured values and pass/fail results are taken from the testers' result files, databases or communication interfaces and matched with the product serial number.

Can poka-yoke checks be done in software?

Checks such as part verification can run in the software layer: the scanned barcode is compared with the bill of materials and a mismatch is shown at the station. Physical interlocks that stop the line stay in the existing automation and are planned with the plant's automation team.

How is OEE calculated on an assembly line?

On assembly lines OEE is usually calculated per line from takt time and planned production time. Station-level cycle and downtime data then show which station the losses come from.

How long does a project take in an appliance or electronics plant?

It depends on the number of lines and stations, the variety of testers and the ERP integration. Projects usually start with a pilot on one line, and the scope is set during the discovery call.