Our quality controls reflect our experience and knowledge gathered over the countless hours spent on production floors all around the world solving manufacturing issues and implementing quality standards.
We are intimately familiar with the common challenges faced by a manufacturer in managing the component supply chain, monitoring parts quality, controlling dispensed adhesives, overseeing curing times and environments, managing work-flow, efficiencies and the overall quality of the work. Current deployed quality control systems heavily depend on the ability and willingness of operators to follow and respect them while sometimes the printed instructions are hard to control and invite deviation and floating away from minimum standards.
From the beginning, it’s our view that processes based on printed instructions and directions open the door to errors and do not cultivate a culture of consistency . Our system generates data that provides the lineage and history of each assembly and the components within each assembly providing, complete and in-depth quality certification.
COMMON QUALITY APPROACH
We knew the shortcomings of implementing common quality approaches to modern transducer assembly. We wanted to create something new, that would gives us deeper control over all the challenges faced in speaker manufacturing...
The basis of this control at REDCATT is found in our quality control and production control software application. A massive in-house project for our software team to code and implement; it embraces all of our ideas and is easily adaptable to our clients specific needs.
Our software infrastructure controls all processes in our factory in a unique interactive manner which keeps operators engaged and accountable. Incoming goods, parts handling through the factory, final assembly data recording, outgoing inspection, shipping, etc. All operations are recorded in a detailed manner while in the factory.
REDCATT QUALITY APPROACH
Because we captured relevant data at every step, we are able to see if dimensions and tolerances are drifting. We can correlate these drifts with the acoustical performance data of the transducer and determine the impact on consistency and quality. This data is shared with your engineering staff to determine future design changes that may yield improved consistency or even higher performance levels. We do this with all processes including adhesives amounts for each operation, we know how long each dispensed adhesives has cured. We capture all testing data and monitor all trends in real time. This allows us to track the status and relate it to schedules and delivery dates.
REDCATT PERFECT PRODUCTION
All REDCATT production line work stations have a full PC setup and large the LED screen featuring visualized work instructions and production data recording. Visualized work instructions are easier to see, and contain highly detailed instructions in comparison to commonly used paper SOPs. Each work station also has a "training" mode dedicated to the product being assembled, the machinery, jigs and tools being used for production. This system ensures each operator is well trained for the job, the specific task is detailed and correctly described, and that the operator sees the latest approved instructions for his or her task.