The Caspian product line consists of four main workstations that operate in the specified sequence. The main workstations include mechanics, wiring, quality control, and final product packaging, which must complete these processes for boards and boxes. Of course, other stations, such as wire and electronics manufacturing, also produce other boards and semi-finished products that have to be assembled on core products. The following figure shows the sequence of production of boards and boxes for production on the line:
Caspian production line process
As the figure shows, the four main stations are purple. The green streams represent the sequence of operations between the main stations. Of course, the workflow of the semi-finished products is shown in yellow line, and the red lines are for refurbishing or refining the products.
After receiving the set of raw materials at the mechanical station, trench drilling processes, installation of duct and spacer, and other elements such as a trans, contactor, cap, etc. are performed according to the plan of each product. Control Panel mechanical map for each product is drafted using AutoCAD software and sent to workstation staff. The products’ barcode is traced to the tray according to the product name, application number, and other parameters, and after the quality control of the products is mechanized and standardized, the products are wired. The wiring process is done according to the specified process and based on the list of BOMs, inputs, and outputs of each wire, the size, and the color of the wires. At the wiring station, boards manufactured by the mechanical station are also assembled. Of course, the process of producing each board is different, but the performance testing is done by the testing machines and then assembled on the board in production. Other semi-manufactured products are also produced at the preparation station for use at other stations.
For special orders customized to the needs of the customer, the materials are a little different and these changes are made at the wiring station and processed according to the barcode recorded in the system and the type of customer request. The materials and the process (wiring and testing) of these products are slightly different, so a separate site is provided for them.
After checking and quality control of the wiring processes, the products are transferred to the final quality control station for final testing. At the same time, the panel’s revision box, which has the same process as the panel, has also been transferred to the final quality control station and site to be finalized with the panel. At this stage, the initial test and the main test are carried out, both in terms of appearance, strength, and functionality of the panel, all processes performed at the previous stations, the products being examined, and if any contradictory standards are observed, it returned. Required modifications are made to the product and tested again according to the checklist and procedure set by the panel. Multi-layer quality control of both the control panel and the revision box makes the failure rate of the products close to zero. In general, the testing process involves checking the accuracy of values, checking labels, mechanical control of boards, wiring strength control, voltage, initial test, and final test. However, board tests are performed both by the electronic station and at the station after assembly on the board. Also for quality control, the wiring map of the boards must be provided to the test station personnel.
After final testing and multi-stage quality control and complete assurance of the technical performance of the products, they are packaged. At this stage, the panel is re-inspected to meet other requirements in the products based on the standards. Also, after finishing the packing process and replacing the tray inside the box, and sealing them in carton board, the barcode of the board is again entered in the system according to the barcode prepared at the mechanical station. This barcode is used to track the product during the production process, sell the control panel as well as facilitate service and products support. The manufactured products are then delivered to the warehouse for sale to the customer.
The production scheduling system is based on routine and special orders and is periodically given to all workstations and warehouses (according to two separate lines) and is constantly monitored.
