Improvement of the Cutting and Bending Process of Component Capacitor Leads

Abstract

This research develops a monitoring and control system for the cutting-bending process that focuses on customer management and component availability to ensure consistent fulfilment of Work Order (WO) Quantities. The system integrates sensors and controllers to detect component conditions and capacitor status at each operating cycle, then transmits data in real-time to a web-based dashboard that displays production metrics, capacitor levels, failure alarms, and actual quantity calculations against Work Order (WO) requirements. With a responsive web interface, operators and supervisors can integrate line performance, intervene quickly when deviations occur, and make decisions based on historical data and performance trends. This implementation was tested on a Cut and Form machine model with parameters measuring cycle time, cutting success rate, and quantity calculation accuracy; This machine can operate according to the desired number of components and can stop automatically once those components have been cut. By utilizing a dashboard system that allows the machine to run according to the number of work orders, efficiency improvements were achieved in the amount deducted ranging from 6.60% to 32.80% and a 100% reduction in scrap quantity