RocketPort - Harley-Davidson

Challenge

Harley-Davidson manufactures more than 800 motorcycle engines each day. In order to maintain strict quality control, an automatic data capture system is in place to ensure product traceability and quality. Comtrol's RocketPort Serial Hub Si is being used to monitor and control engine manufacture at Harley-Davidson as part of their statistical process control initiative. It is also being used to develop a database of all parts and products shipped.

Technology Solution

The process control system, which links in with existing factory floor equipment, is integrated with a new central Assembly Line Monitoring System (ALMS) server, new assembly line controllers, and utilizes existing assembly line devices to identify the incoming engine, provide the operator with applicable assembly information, and monitor and control operations during the assembly process. The system also determines the Pass/Fail status for each individual process step, automatically advancing the system when the process passes and automatically stopping the system from advancing if the process fails or is not completed.

The engine assembly data associated with an assembly station is collected through several types of devices, compiled, and transferred to a central computer, which stores the information in its database. These devices, such as torque and gauge tools, attach to the RocketPort Serial Hub Si to enable seamless transfer of data. During the build cycle, the information transfers to Harley-Davidson's existing host system, which stores the information as part of the engine's history for later reporting.

The RocketPort Serial Hub Si also transfers feedback data to assist and monitor the operator at each assembly station.

"The RocketPort Serial Hub Si's are so reliable and easy to work with, we plan to install 30 more next year. It puts control at the station-we avoid rework costs because we do it right the first time" -Operations Engineering Manager Harley-Davidson