LSI has sold hundreds of systems to the HVAC, Elevator, Generator and Appliance industries for over the past two decades.
We have significant experience with assembly line automation and product testing from critical component verification, functional run test, integrity testing, liquid charging, and lay-in/WIP stations.
Fundamentally there are two types of DALS testing stations:
- An Assembly Process station contributes to the progressive assembly of the product.
- A Test Qualification station which evaluates the product at a particular point in the assembly through a series of applied tests where measurements can be taken and compared to pre-set high parameters and low parameters.
It is possible to have both types of stations combined in some format into a single process.
DALS stations can be used in a stand-alone process or networked with other DALS stations providing for an integrated quality solution. The minimum hardware DALS configuration is a networked PC with a barcode scanner and/or printer.
Typically DALS stations incorporate I/O systems that are installed inside the PC in a slot or installed exterior to the PC in a rack-mounted system. Advanced DALS stations have the I/O systems plus other specialized test systems connected to the PC through serial communications.
DALS software is a complete production package designed for the plant floor.
Within DALS is a suite of programs that interact to provide a solution in a variety of assembly operations and testing qualifications. DALS is a .NET based software package that resides on a personal computer (PC) and operates with the latest Microsoft Operating Systems.
DALS stations share their connectivity on the plant floor through a common SQL database.
Each DALS station type, located on the plant floor, is stored in the database with its plant floor location; typically plant floor locations are defined by Line Number or Line Name. All DALS stations that share the same assembly line, intercommunicate to provide unit assembly progress and status. As the assemblies proceed from one DALS station to the next, “real-time” test data is generated and saved in the database. DALS’ bottom-up approach gets production information “up to” manufacturing reporting services or other production resources providing real-time information to supply chain management systems.
DALS is designed to operate with a stand-alone SQL database on a server allowing users to access and use “canned” reports embedded in DALS or use Microsoft’s SQL Server Reporting Services or other 3rd party software that can access SQL databases. Additionally, DALS can report to SAP or an existing AS400 or management computing platforms.
Each product being assembled must pass a DALS station’s assembly process or test qualification before it is allowed to continue to the next station.
Every time a product under assembly (PUA) is scanned in a DALS station, it is evaluated to determine if all previous tests or required processes have occurred and passed within proper parameters. This is called process interlocks. Only PASSED PUA’s can advance through the process.
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Although DALS offers a complete assembly line solution, partial or single station installations are very common. Product choice is directly driven by the customer’s needs. Then as other assembly needs or long-term goals are implemented, additional products are added leveraging DALS’s flexibility.