Untersuchung und Lenkung von modernen Fertigungsprozessen mittels rechnerunterstützter SPC einschließlich Planung, Konstruktion und Bau einer mit Induktivtastern bestückten Messvorrichtung Erasmus Project

Project Title

Untersuchung und Lenkung von modernen Fertigungsprozessen mittels rechnerunterstützter SPC einschließlich Planung, Konstruktion und Bau einer mit Induktivtastern bestückten Messvorrichtung

Project Key Action

This project related with these key action: Cooperation for innovation and the exchange of good practices

Project Action Type

This project related with this action type : Strategic Partnerships for Schools Only

Project Call Year

This project’s Call Year is 2015

Project Topics

This project is related with these Project Topics: ICT – new technologies – digital competences; New innovative curricula/educational methods/development of training courses; Research and innovation

Project Summary

Every day, thousands of identical parts are produced in a modern mass production based on the division of labor in automated manufacturing.
Since constant monitoring is highly uneconomical, only a random sampling test is performed, the scope of which is fixed.
The results of these random tests are used to generate statistics that reflect the quality of all parts produced. The production process is monitored and controlled by statistical process control (SPC).
An essential goal of the project was to increase the professional competence of the trainees. In addition to the development and manufacture of the required measuring device, the understanding and necessity of statistical process control in the area of ​​product quality and process quality monitoring has been achieved.
In addition, the participants were informed about the German-Polish history, the culture of their partner country. Working in groups has increased the social and personal skills of the participants. In addition, the ability of participants to use modern media for the communication, presentation and interpretation of measurement results has been improved. Last but not least, the partnership between the two schools was intensified with this project.
Each school was involved in the project with 12 apprentices and 3 teachers. The participants of the TGS BBZ Neunkirchen were apprentices from the fields of industrial and tool mechanics. The students of ZMS No.1 in Krakow were apprentices with the aim to become mechatronics technicians.
The content specified in the curriculum of the trainees for monitoring product quality and process quality was sustainably implemented with the help of the project.
The participants carried out measurements to determine the machine and process capability, collected process data and calculated characteristic values, which were evaluated with the aid of graphics. The evaluations were based on statistical methods of quality assurance in series production by means of a software application.
In several joint training sessions in English, the project participants were introduced to the theory of statistical process control in more detail.
SPC companies trained all participants, both German and Polish participants, in dealing with the required measuring software.
Both partner schools chose a gear shaft as the workpiece and set test characteristics; Concentricity and diameter of the shaft at defined points. As a result, a measuring station was developed and technically implemented by both schools. In addition to the shaft mounting, the measuring stations consist of four inductive measuring probes and a linear drive required for concentricity testing. In order to be able to implement an automated measurement process, the trainees configured the necessary electropneumatic components. The handling of the waves to be measured was carried out by a school-owned industrial robot. The shaft storage was a 5×5 pallet equipped with a recapturing unit. This was designed by the trainees and manufactured with the help of a 3-D print. The overall process was structured using a Grafcetplan.
Thus, the participants of the vocational training centers developed a technically sophisticated mechatronic system that meets the requirements of Industry 4.0.
After the successful trial run, the trainees of both schools produced 25 more waves each. The test of these 50 waves made it possible to check the machine capability. In addition, the data obtained were analyzed for their standard distribution. Quality control chart could be generated.
As a long-term advantage, subsequent generations of apprentices can use the measuring station consisting of measuring station, measuring computer and shaft storage.
The results of the project were presented to a wide audience of politicians, representatives of school boards, chambers of trade and training companies at both schools.
For the presentation in Krakow, both measuring stations were linked together.
In addition to their use in class, the measuring stations can be used in the future as a presentation object and demonstrator at educational fairs and similar information events.
During the mutual 10-day visit to the European twin city, the focus was not only on developing technical solutions but also on cultural exchange.
An intense exchange and varied supporting programs in the respective country made initial restraint between the international student groups disappear and friendships emerge. The German-Polish history was discussed and the students were informed about cultural backgrounds, history and politics. Thus, the trainees also got a deeper insight into everyday life in each host country.

EU Grant (Eur)

Funding of the project from EU: 45450 Eur

Project Coordinator

TGS BBZ Neunkirchen & Country: DE

Project Partners

• Zespol Szkol Mechanicznych nr 1 im. Szczepana Humberta w Krakowie