Managing Defects on the Fly. How do MES Systems Optimize the Handling of Defective Products?

The occurrence of defective items in production is an everyday reality for every factory. The key to maintaining profitability is not only preventing errors, but also the ability to properly manage them when they do occur. This process is supported by modern MES (Manufacturing Execution System) class systems, which enable advanced defect handling. Thanks to this, operators can classify and manage non-compliant products without interrupting ongoing production.

Traditional systems often force employees to simply mark damaged parts as "defects". This, however, blurs the picture of what is actually happening on the production line. This approach is prevented by Production Execution in the Operator platform.

The Production Execution module is an MES terminal that becomes a communication channel between the production hall and the system. In addition to comprehensive production reporting capabilities, the terminal enables advanced waste reporting (so-called outsort management). It supports the disposal process while simultaneously allowing for the introduction of all corrections, performing repairs, and handling so-called re-work products.

The result? Operators gain the ability to accurately determine the causes of errors. Because of this, subsequent quality analysis becomes a solid foundation for minimizing material losses.

Managing defects on the fly requires a flexible approach. The Operator system offers five main classification paths for units that require additional intervention:

• Direct Repair – a feature that enables direct repair of a defective part without interrupting ongoing production. The operator can repair the product on the spot and immediately return it for further processing.
• Repair – involves repair actions at the production workstation, but they are performed at a later time. This can occur, for example, after the completion of the current production run.
• Rework – otherwise known as reworking defective goods. This allows you to modify products and give them a new material code or create entirely new products.
• Scrap – the final classification of a product as waste that is unsuitable for further processing or repair.
• By-products – these are elements or semi-finished products created during the manufacturing of the main product. Parts classified this way can be effectively utilized in future production processes.

When we free operators from the necessity of working at stationary terminals, quality management becomes much faster. The Operator Mobile App enables the registration and classification of production waste directly at the workstation. In turn, the Quality Control module guarantees immediate quality monitoring at all stages of production.

Mobile solutions also facilitate access to data on quarantined products. Thanks to this, it is possible to report test results and streamline their release process.

Entering the causes of rejections and errors in real-time provides invaluable information for the entire factory. It allows for a comprehensive analysis of production quality on an hourly or shift basis. Furthermore, the precise identification of defective batches will allow for targeted product recalls and cost reduction.

Treating quality defects as an inherent element of the process and implementing tools to manage them on the fly is a huge step towards Industry 4.0. Instead of stopping the entire line, employees can act in a planned manner. In the future, the data collected in the MES system will allow for the elimination of bottlenecks in the area of quality.

Do you want to check how such a solution will work in your factory? If you are in the process of looking for a system to optimize production, we invite you to contact us and schedule a demo.