High-speed for your shop floor.
An offer by IGH.
What we are offering:
Intuitively operated test systems that enable OPERATORS to perform manufacturing, testing and task-documentation quickly and in a guided, standardised manner.
A parameterisable platform that can adapt PRODUCTION PLANNING to all products and requirements. Consistently networked software that provides all shop-floor data to QUALITY MANAGEMENT in real time, thereby delivering the foundation for making decisions in process optimisation.
A scalable solution that enables TECHNICAL and STRATEGIC MANAGEMENT for monitoring central KPIs and managing integrative production for both the individual plant and throughout the group.
And a clear plan of how these promises
can be put into practice.
The AQIs platform - Made for the shop floor 2.0
[a:kiss] = Advanced Quality Inspection system
Two statements on the nature of AQIs:
AQIs is not a hard-coded stand-alone solution, but a networked database-based digitisation platform that can be parameterised for specific tasks.
Thanks to its scalable, integrated approach and modular design, AQIs can visualise the most diverse of shop-floor applications in one use case – and interact with assembly groups, individual wagons and trains, gather data and store it in digital product files, track errors across locations and much more.
Our aim is to optimise, standardise, automate and digitise the production and quality assurance processes on your shop floor in such a way that you obtain a highly economical, high-quality production facility that delivers on time, can be reliably planned and achieves all KPIs.
AQIs is being successfully used by
numerous customers for many years.
Overview of modules
for one plant
The product range
AQIs Product Configuration
If ERP communication is missing or impaired, the
product configurator is used to enable job-compliant
testing, with:
- Create and configure units under test (based on
reference lists and catalogues) - Store setpoints and important properties for each
unit under test where order data cannot be
provided by other systems and thus no order
parts list is digitally available. - Change of configuration after start of assembly
in order to perform tests with new data - Documentation of results in the AQIs database or
transfer to other IT systems
AQIs Information System
- The AQIs Information System is a web application.
- The AQIs Information System allows important
key indicators and fault information in production
or maintenance to be captured, visualised and
communicated. - Important information such as track occupancy,
deadlines, work progress, error status, residues
and KPIs (e.g. OEE) can be displayed on Andon
boards that are positioned in visible locations in
the production shops. - Digital fault management is integrated. Whenever
a problem occurs in production, a responsible
employee can be called to resolve the problem.
AQIs Report
- AQIs Report is a web application.
- AQIs stores all result data and errors in the digital
product file. Using a range of templates, all manner
of reports, statistics and KPIs can be generated
from this. - Possible reports include: Error frequency, repair
times, digital product files, measurement value
and parameter report. - Reports are used for production optimisation in
respect of the production and maintenance
processes, product development and personnel
development.
AQIs Rework Control
- AQIs Rework Control allows the reworking of all
errors to be planned, prioritised and performed
until the unit under test is error-free. - Where resources are limited, sequence planning
can take place in priority lists. - With scheduled times for each repair and the
planned completion date, an overview is always
available of the staff utilisation levels and the
resources required. - Operators can use a web application to accept
their work list, view all error details, document
the repair and clear the fault.
AQIs IT system communication
- AQIs supports interfaces for all current ERP
systems such as SAP and also interfaces to web
services and SQL and ODBC databases. - Data from suppliers and from test stands from
other manufacturers (standalone solutions) can
also be integrated. - The interfaces operate in both directions and
support a range of file formats.
AQIs Dashboard
- Dashboards are used to visualise relevant
signals (tacho, switch, buttons etc.) so that - Relationships between input and output
signals can be detected immediately. - Dashboards are therefore useful for
iterative settings tasks or tests on
prototypes or special solutions. - Any number of dashboards can be set
up in ways that are freely parameterisable,
variable and versatile. - The dashboards communicate with the
unit under test and the measurement
technology via the interface library.
AQIs Administration
Basic settings are made in AQIs Administration
- Parameterisation for use of AQIs
- User and rights management
- Classifying error codes
- Series with options and variants
- Setpoint management
- Localisation
- …
AQIs Interface Library
- The AQIs Interface Library enables practically any testing task or test to be realised.
- Various different signals can be sent, different bus systems can be linked and assembly
groups can be actuated individually. - The interfaces to sensors and actuators, to controllers and to external systems, are
constantly being expanded. For assembly groups, the (missing) residual system is
also simulated via interfaces.
Important interfaces include:
- Beckhoff I/O, EtherCAT terminal and bus terminal system:
- Sensors
- All common sensors:
- Standard interfaces 0…20 mA, 4…20 mA, 0…10V, -10…+10V
- AC/DC current and voltage; any power output
- Frequency measurement
- Pressure measurement, pneumatic or hydraulic
- Force measurement, e.g. strain gauge or load cells
- Displacement and time measurement
- Speed measurement
- Other sensors with electrical or bus interface (e.g. IO link)
- All common sensors:
- Actuators
- Standard interfaces 0…20 mA, 4…20 mA, 0…10V, -10…+10V
- Digital outputs: 24VDC, 110VDC, for contactors and relays
- Analogue outputs
- Sensors
- Linking of complex measuring instruments
- Linking of complex power supply units and function generators
- Linking of frequency inverters
- Integration of safety circuits: Emergency stop, light curtain, security sensors
- Bus communication: EtherCAT, Raw CAN, CANOpen, KWP2000, UDS, OBD, J1939,
Profibus, Profinet, serial protocols - More protocols: OPC-UA, MQTT, DDS
- Integration of drivers, libraries, APIs
- Web services
- Residual API
- Customised protocols
- Various databases
- Beckhoff I/O, EtherCAT terminal and bus terminal system:
AQIs Test Sequence Configuration
- AQIs Test Sequence Configuration is used to parameterise
test sequences that image the test, commissioning and
acceptance processes of the customer. - Manual testing and documentation tasks are largely
automated and digitised. - Different variants and options for units under test,
order-specific setpoints and particular details are taken
into account. - AQIs Test Sequence Configuration conserves expert
knowledge for the future in a transparent manner. - This makes test processes independent of specific
individuals, transferrable and reproducible.
AQIs Fault Management
- AQIs Fault Management is a web application.
- With AQIs Fault Management, digital
errors that are detected on the unit under
test during the production or maintenance
process can be captured,
documented, traced and resolved at any time -
independently of questions in checklists
or measurements taken on test stands. - A unified description of errors is achieved by
means of classifying error codes. - Individual documents and handwritten notes
are no longer necessary. Errors are communicated
digitally in real time, automatically and without
media disruptions. - Photographs can be taken to document an
error directly in the error management system. - All data is stored in the AQIs database and
exchanged with other systems.
AQIs Checklists
- AQIs Checklists are a web application. AQIs
Checklists are used to implement a digital
operator assistant, to document processes
and data and to support quality assurance. - These replace manually compiled logs,
paper checklists and files managed on a
decentralised basis. - All documents are maintained
centrally and made available in real time
via the AQIs Checklists.
AQIs Testing
- AQIs Testing is the runtime environment
of the test stands. - The test sequences, previously parameterised,
are handled by largely digital, job-compliant
processes and digitally documented. - Errors and deviations detected during the test
execution are documented and communicated
digitally. - In the case of assembly groups that are not
installed, AQIs Testing simulates the surrounding
system. - AQIs Testing communicates with the unit under
test and the measurement technology via the
interface library.Messtechnik.
Test station
for assembly groups, individual wagons and trains
Electrical and functional tests for assembly groups, individual wagons and trains are carried out at the AQIs test station. The test computer is connected to the unit under test via the interface library. The connection is made using electrical signals and/or bus interfaces, including wireless interfaces.
It is possible to integrate IoT modules and/or existing test systems, e.g. TrainTracer, simulation bays and communication DLL bidirectionally. Residual system simulation can be used to simulate the installed situation for assembly groups. The electric power supply to assembly groups or individual wagons can be provided via the AQIs test stand.
Structure of the digital work station
Communication between
SAP and AQIs
A brief look into the AQIs software
What makes AQIs
so unique?
AQIs
has been developed
precisely for the requirements of
the shop floor.
AQIs
is standardised and at the same
time can be individualised to a high
level by the operator.
AQIs
provides data in real time – to all stakeholders at the plant and in the corporate group.
Assembly groups can be tested before installation with the aid of residual system simulation.
AQIs
reduces costs with consistent
digitisation, automation and
parallelisation.
AQIs
achieves a significant
reduction in errors thanks to
100% monitoring.
AQIs
cuts test times, reduces
turnaround times and cuts the need for personnel.
With rapid customisations or expansions to accommodate new requirements, AQIs is a secure investment.
AQIs
supports almost all common
interfaces (SAP, MES, DMS, SQL, Webservices etc.)
After production
comes maintenance
Same processes, same modules, new task
Vertical expansion
The use of AQIs in a pilot plant can be rolled out with the same use scenarios and with a parameterisation adapted for other series at other plant. A synchronisation service provides all local data from a central point. Use of AQIs can be administered centrally and the results can be evaluated throughout the company group.
Following detailed planning, IGH offers a turn-key, customised solution for digitisation and automation in production, quality assurance, commissioning and documentation.
‘Office package’ for production and maintenance | Networked, seamless, database-based software platform | Widely customised parameterisation | Release-ready & established
IGH liefert die Standardsoftware AQIs, die über Parametrierung sehr kundenspezifisch angepasst und erweitert werden kann. AQIs wird eingesetzt für
- Prüfsysteme – stationär und mobil – mit Sensorik und Buskommunikation für
- Baugruppen (Subsysteme)
- Einzelwagen
- Züge
- mobile Webclients zur
- Qualitätssicherung
- Dokumentation
- Werkerassistenz
- Reporting und Statistik
- Nacharbeitssteuerung
Alle AQIs Clients sind im Intranet vernetzt mit anderen IT-Systemen des Anwenders, wie z.B. SAP.
The AQIs test system, highly parameterisable in multiple dimensions, is a platform that can be adapted and expanded on a highly customisable basis.
AQIs is used for:
- Stationary and mobile test systems with sensors and bus communication for
- Assembly groups (sub-systems)
- Individual wagons
- Trains
- Mobile web clients for
- Quality assurance
- Documentation
- Operator assistance
- Reporting and statistics
- Rework control
All AQIs clients are networked on the intranet and with the user’s other IT systems, such as SAP.
The Customer is a stakeholder for the test system, defines the requirements and integrates the AQIs platform into its own IT infrastructure.
Description of processes and requirements | Implementation and hosting of IT solution | Adoption of manufacturer’s responsibility | Coordination of required authorisations | Active project involvement
Alstom beschreibt die Prozesse sowie die Anforderungen an das Prüfsystem und die notwendige Parametrierung der Softwarelösung im Sinne des Customizings auf die Anforderungen der kundenspezifischen Prozesse. Hinzu kommen:
- Implementierung und Hosting von AQIs gemäß der von IGH spezifizierten Regeln auf Alstom-eigenen Systemen
- Integration und Anbindung von AQIs an andere, Alstom-eigene, IT-Systeme (z.B. SAP, DMS, BDE, MES, …)
- Übernahme der Herstellerverantwortung, falls AQIs-Komponenten auf einzelnen Komponenten / Baugruppen / Subsystemen, Einzelwagen oder gar ganzen Fahrzeugen verbaut und mit ausgeliefert werden
The customer describes the processes and the requirements for the test system and the necessary parameterisation of the software solution in terms of customisation of the requirements of the customised processes. Other features include:
- Implementation and hosting of AQIs in accordance with the rules specified by IGH on the customers own systems
- Integration and linking of AQIs to other customer-based IT systems (e.g. SAP, DMS, PDA, MES etc.)
- Adoption of manufacturer’s responsibility if AQIs components are installed on individual components / assembly groups / sub-systems, individual wagons or indeed entire vehicles and supplied with them
Project steps for shop floor 2.0
Gathering of requirements & analysis on-site
Workshop fine planning & timeline
Proof of concept
Pilot system
Roll-out
Start with phase ZERO: the discussion about your shop floor 2.0
High-speed for your shop floor.
An offer by IGH.
We would be happy to discuss this proposal with you in more detail.
Ludwig Hoppe
Director | Managing Partner
IGH Automation GmbH
The presentation given here is the intellectual property of IGH Automation GmbH. As such it is subject to the applicable copyrights. Any unauthorised use, duplication in whole or in part or any disclosure to unauthorised third parties is not permitted.