Knorr-Bremse Vasúti Jármű Rendszerek Hungária Kft. is involved in the manufacturing of railway brakes and their accessories. Precision and technology compliance are highly essential. Under no circumstances may faulty or inaccurately manufactured end-products leave the factory as that could have dire consequences. Precision tools and equipment are used in manufacturing, which must be tested at regular intervals. All the tools must be tested on site in the factory hall since their movement is difficult or impossible due to their size and weight. The process had formerly been paperbased but the administration and tracking of these documents were problematic.

Another problem posed by the paper-based method was the on-site selection of the right form from the many different types. Following testing, processing and entry into the computer represented further potential sources of data entry errors.

For the purpose of the testing of tools, BCS Hungary has developed a solution consisting of mobile terminals and desktop computers. The central element of the system is a Microsoft SQL database hosted on a reliable server computer. Authorised users may modify or query the different master data and tasks via a PC.

Testing is performed on site using the Motorola/Symbol MC9090-G devices supplied by us. The system and the related database have been built so that they will operate fast and reliably even when a large number of tasks are being carried out.

The program works offline on the mobile terminals. The device stores all the collected data in its own memory until the next download. This enables work to be performed also in areas without WLAN coverage.

At shift start, the user compiling the task can compile the list of tools to be tested on that day with just a few clicks. This user may assign different testing parameters to the different tools and may also set the frequency of required checks.

Following the compilation of the list, the testing task must be loaded into the terminal. This may mean the testing of up to several hundred tools. Using the built-in bar code reader of the mobile device, each of the different tools can be identified in the factory hall easily, without any risk of error, based on its unique bar code. Given that the tools are located at various points around the factory, the terminal can be used to query the list of devices not yet tested.

Once a tool has been located, its key data (place of manufacturing, place of storage, time of latest testing, type, description, etc.) can be displayed on the mobile terminal following the tool’s identification to make sure that we are facing the right tool.

Testing is done based on the questions displayed on the screen of the mobile terminal. Results can easily be entered through the touch-screen. For example: Running all right?, Engine operating?... By completing all the questions, a full test can be done for the given tool. The system ensures that no question is skipped, thereby guaranteeing that testing is complete and secure. Upon answering all the questions, the program indicates the end of the process. Only then can we proceed to the next tool.

Following the completion of this work, when the results are downloaded from the mobile terminal into the PC, the data appear in the system’s SQL database, too, thereby avoiding multiple data entry and reducing the chance of erroneous action.

The listing of improperly operating tools during the evaluation is now just a few clicks away. The list thus compiled can be printed, exported and forwarded to the competent staff, who can then conduct the repair or perform any necessary replacement. This may result in a significant reduction of the downtime of tools.

The PC interface can be used to make various queries, reports and summaries and data can also be saved in Excel sheets.

The introduction of this solution enables Knorr-Bremse to conduct quality tests of tools in a far quicker and more reliable manner, thus enabling the achievement of a higher level of precision in the manufacturing of end-products. This means that any faulty manufacturing caused by defective tools can be avoided, which translates into significant financial savings.

Tool defects recognised and registered at an early stage can be repaired quickly, thereby increasing the efficiency of manufacturing and productivity.

Another business benefit is the fact that, in addition to testing, the register of tools will also be more precise, e.g. the storage place function of the program indicates where the tool is located, periodic tests can also be better scheduled and responsible persons can be assigned to tools submitted for repair.

The MC9090-G terminals supplied are universal devices, which can be utilised by their user also for other tasks during the manufacturing process. This enables any out-of-service mobile devices submitted for repair to be substituted with terminals used for testing.