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The Exacta® Plus Process Control System
Exacta® Plus • Designed to increase the efficiency of jobs that require multiple tasks, such as audits and sequential manufacturing processes.
Exacta® Plus Architecture • The system architecture utilizes a powerful software program and the Exacta® Plus digital tools. • The program can run on a network or as a stand alone system.
Exacta® Plus Process Glossary • Each tool can store one “Job” at a time. • A “Job” is a specific group of 1 to 50 “Tasks. ” • A “Task” is a set of up to 50 common “Records” dedicated to a particular joint or assembly. • A ”Record”consists of parameters for a single fastener.
Exacta® Plus • A job is selected and assigned to an operator and a tool. • A work order/job card is printed that describes each task and the tools required to accomplish the job. The job is downloaded to the tool.
Exacta® Plus • Using the information from the job card the operator enters a task and record location via the 4 button keypad on the wrench.
Exacta® Plus • Once the task is selected the display shows the minimum torque value to be achieved. • Once the torque operation is completed the value is recorded, automatically clears and the next record is cued.
Exacta® Plus • Once all of the records in the task are completed it is closed and automatically opens the next task. • As before the operator selects the record and repeats the process.
Exacta® Plus • When all the tasks for the job are completed the operator uploads the data to the network or returns the wrench to the crib.
Exacta® Plus Job Report
Exacta® Plus Data Detail Report
Exacta® Plus Software Requirements and Export Capability • The software requires and is compatible with Windows 2000 SP 3, XP and Windows server 2003. • The database is capable of being exported to other programs in ASCII comma delimited or user defined delimited fields.
Sturtevant Richmont Global Reach. Local Support. Exacta® Plus Overview October 2005
Glossary Review • A “Record” is an individual fastener on an assembly. • A “Task” is a group of from 1 to 50 fasteners sharing the same specifications on a single assembly. • A “Job” is a group of from 1 to 50 Tasks that are treated as a single group for use on a tool. • A “template” is a description or definition.
Seven Step Simplicity • Install the software. • Tell the software where the tool will be connected to the pc. • Tell the software what tools you have. • Tell the software who your people are. • Tell the software what the characteristics of each joint are. • Tell the software which joints, tools, and people go together into a job. • Assign the job to an individual person and single tool.
Step 1 - Install • Insert the cd into the pc. – An Install Shield Wizard activates and guides you through each step. – One button – “Install” - handles 90% of the work and makes the process easy. – Just click on the obvious choices. • Eject & store the cd.
Start the Software • For the first use: – Username = admin – ID Number = admin – Password = admin • Type them in and click the Login button.
Step 2 - Communication • Communication merely means telling the software what port will be used to connect to the tool(s). • COM 1, COM 2, and COM 3 are the most common choices. • The COM port number that correlates to the serial port is the one to use.
Step 2 A • Everything ahead of downloading a job to the tool is an admin function. • Click on the “Administration” button to proceed.
Step 2 B • The Administration screen provides selection of the admin function to be worked on, and will be used throughout. • Click on the “Hardware” button to set up tool communication.
Step 2 C • Select the route to the tools by using the “Serial Port” pulldown. – The list of available ports will open up. – Click on the port to be used. • Leave the rest. • Click on the “OK” button to close.
Step 3 – Tool Population • The software needs basic information about the tools that are available, such as serial numbers and capacities. • In this step we tell the software what tools are available for use. • Connect the serial cable to the pc for convenience in this step.
Step 3 A • Adding tools is an admin function that starts from the admin screen. • Click on the “Tools” button to access this function.
Step 3 B • The “Tool List” screen is a list of the tools in the system, and an access point for changing them. • Too add a tool, click on the “New” button.
Step 3 C • Two options: – Type in all of the info for the tool. – Connect the tool and use the “Request Tool Information” button, then type in only the balance. • When done, click the “OK” button.
Step 3 D • The “Tool List” screen will reappear with the new tool added to the list. • More tools can be added the same way, but for now just close the screen to proceed.
Step 4 - People • This step tells the software what people will use it and how we allow each one to use it. – “Rights” are capabilities. – Rights can be assigned in a group or individually. – There are four predetermined groups of rights. • Typically some users will only be able to do jobs with the tools and others will be able to perform admin functions.
Step 4 A • Adding and managing users is an admin function that starts at the “Administration” screen. • Click on the “Users” button.
Step 4 B • The User List screen shows the users in the system and the characteristics for each. • To add a user, click the “New” button.
Step 4 C • Type in the information for the user. • Click the “Help” button for a complete explanation of “Rights” and “Security Levels”. • Select the Security Level (pulldown) and any individual Rights (check boxes) to be assigned to this person. • Click the “OK’ button to add the person to the list.
Step 4 D • The new person just added will show up on the list. • More people can now be added, but for now click the “Close” button to proceed.
Step 5 – Task (Joint) Templates • In Exacta Plus, each joint is a “Task” defined in a template. • Just as the software needs to know what tools are available and what people will be performing what work, it needs specifics on each task to be performed. • Task templates are the building blocks that will be used to create jobs; tasks are downloaded to, and used by, the tools.
Step 5 A • Creating and managing tasks is an administrative function. • Click on the “Task Templates” button.
Step 5 B • The Task Template List shows all existing templates, and is the means for managing them. • To add a new task template, click on the “New” button.
Step 5 C • Fill in the number of records (fasteners), warning torque, Low and High torque specification numbers. • If all nut torques must be recorded, check “Required”. • Select mode of operation and whether tool light will be used. • Add socket size, task description (name) and location. • Click the “OK” button.
Step 5 D • The new task template will show up on the task template list. • More tasks could be added (or deleted, or edited) from this window, but for now simply click the “Close” button.
Step 6 – Jobs or Routes • The people, tools, and joints (task templates) have been defined. What remains is to pull them together into “Jobs” (another template). • A Task can be used in multiple jobs. • A Job template can be stored and used repeatedly; to differentiate the data it will have a different name each time it is used.
Step 6 A • Designing and managing Job templates is an administrative function. • Click on the “Job Templates” button
Step 6 B • The Job Template List shows all the jobs currently in the software. • To create a new job template, click the “New” button.
Step 6 C • Select the tool capacity to be used on this job; tasks outside that capacity will be blocked from use. • Highlight the first task to be performed and use the green left arrow to add it to the job. Repeat for each task to be part of the job. • When finished adding tasks, click the “OK” button.
Step 6 D • The new job template will show up on the list. • From this screen more job templates can be added (or edited or removed) but for now click the “Close” button.
Step 7 – Job Creation • The Job is actually created when the job template is: – Assigned to a specific tool, – Assigned to a specific individual, – Assigned a unique work order number. • A customer ID and unit number are also available to assist in identification. • When done, a Job Card (specific instructions) for the job can be printed.
Step 7 A • Job creation is an administrative function. • Click on the “Jobs” button.
Step 7 B • The Job List will show all current jobs; those awaiting download and those already in process. • To add a new job, click the “New” button.
Step 7 C • Use the “Filter Tools By Capacity” and/or the “Tool Serial Number “ functions to select the unique tool to be used. • Assign a unique Work Order Number. • Assign a user (Worker) to the job. • Add a Customer ID and Unit Number. • Select the Job Template. • Click the “OK” button.
7 D • The new job will show up on the job list. • More jobs can be added (or deleted or edited) from this screen, but for now click the “Close” button.
Ready for Use • The software now has its’ first job ready to be downloaded to a tool. • The steps to add tools, users, task and job templates, and actual jobs are the same as those shown here. • The software manual and help functions have extensive context-sensitive information that helps prompt you through any task in the software. It also has instructions for using advanced functions (filters, etc. ) and exporting data for use elsewhere.
Administration - Users • Management chooses the level of control it wants over the process of creating, selecting and assigning tasks and jobs.
Administration – Users 2 • There are 4 levels of security and within each level, there are 5 assignable rights.
Administration – User Security • This excerpt from the screen specific “help” guide in the Exacta Plus software details the Security Levels and Assignable Rights.
Administration Tools Hardware Configuration
Hardware Configuration Help Screen
Administration - Tools • Tracking the tools calibration cycle is done at the push of a button. • Certification can be date based or use based reducing the cost of unnecessary calibration for tools that are infrequently used.
Administration Tool Backlight • The tri-colored LCD backlit display is an important feature of the Exacta Plus. • The lights can be enabled when in PEAK mode to assist an assembler or disabled to avoid influencing an auditor. • When enabled for residual mode the value will appear with a green backlight “OK” or Red for “Bad”.
Administration – Task Template • Audit routes can be created from the Task template data base. When creating a task certain attributes pertaining to the task can be selected. • Certain critical joints (tasks) will be highlighted on the job card indicating that all records for that particular task are required • The selection of Peak or residual mode for hard joints can be selected. • The tri-colored LCD backlight can be enabled or disabled
Administration - Job Template 1 1. To create a job template first select a tools capacity 2. Tasks outside the tools range will be highlighted in red 2 3. Create a name for the Job Template
Job Creation • To select tasks for the job simply highlight (in blue) the Task and click on the arrow. • Use the arrows or “click and drag” to rearrange the sequence of tasks within the Job.
Administration Job Template List
Administration – Job Card • The job card is printed out with option of leaving the validate number empty. If a roving auditor finds a defect this field can be used to record the serial number of the defective product. This field can be edited when uploading the completed job.
Manufacturing Applications Utilizing Exacta® Plus • • Auditing Power Tool Validation Repair and Maintenance Non-Automated Sequential Manufacturing Processes