Tag: automotive

Rockwell Automation Global Solutions team project manages, designs and delivers complete door module assembly line for PHA Czech s.r.o.

Leading automotive tier one leverages project management, technical capabilities and class-leading Integrated Architecture products from Rockwell Automation

Background: Pyeong Hwa Automotive (PHA) is a world leader in the automotive subassembly business. Headquartered in Korea, the company operates seven plants in Korea, seven plants in the Czech Republic, Slovakia, China, India and the USA and three worldwide sales branches.

The company’s Czech Republic plant, PHA Czech s.r.o., in Český Těšín, 300 km east north of Prague, started production in 2008 and employs 300 people. Its primary focus is to produce door modules for a leading Korean automotive original equipment manufacturer (OEM). However, it also produces non-module door hinges, bonnet/hood hinges, tailgate hinges and tailgate latches for a number of other leading automotive OEMs.

In a recent development programme, the Rockwell Automation® Global Solutions team in the Czech Republic was tasked by PHA Czech s.r.o. to develop a complete control solution for a front/rear, left/right turnkey door module assembly line and end-of-line (EOL) test stations. The project scope for the team, which has been working with PHA since 2006, involved project management, administration, hardware and software design, cabinet manufacture, site installation, commissioning and production start-up.

Challenge: The assembly line – the fifth to be developed by Rockwell Automation for PHA – had to be designed to meet demanding production capacities and targets; capable of building 850 car sets per day, yet flexible enough to support building up to 1,000 car sets per day. It also would be the first door module line built on a conveyor concept, where the panels move on pallets and the operators stay in one place.

In addition, PHA wanted enhanced quality levels and various process optimisation steps based on both knowledge from previous installs and newer standards and targets defined by more recent end-user customer requirements. A comprehensive machine and personnel safety solution was also part of the brief.

Solution: For the complete door module car set assembly, there are two lines (front and rear) with conveyors carrying the front door module down one side and the rear down the other. These modules are then assembled in parallel using an identical sequence. Assembly operations include: pulley pre-assembly and riveting; drum winding; window regulator assembly; motor and speaker assembly; latch placement and the incorporation of a side-impact sensor and wire harness. The end-of-line (EOL) inspection stations then undertake full door module functionality tests and motor noise sound inspection (in a sound room), deploying a Poka Yoke quality system.

According to Rockwell Automation Account Manager Miroslav Novotny: “This was a complex project, which was made easier thanks to our Integrated Architecture® portfolio. The main line controllers on the front and rear lines are Allen-Bradley ControlLogix® 1756 L73 programmable automation controllers (PACs). The chain conveyors and motors, which handle all aspects of pallet movement are controlled using Allen-Bradley PowerFlex® 525 variable-speed AC drives. This comprises lateral and up and down movement of the pallets between workstations, and control of the recirculating conveyor, which takes empty pallets back to the beginning of the production line.”

The ControlLogix PAC collects, collates and controls all the signals from the various assembly stations using Allen-Bradley Stratix™ managed switches and Allen-Bradley POINT I/O™ modules on an EtherNet/IP™ network. This is to accommodate the long distances involved, including the primary conveyor which is 15 m long. At the end of the line, in the testing stations, four Allen-Bradley CompactLogix™ PACs are used, two in the sound rooms and two in final inspection. The ControlLogix PAC also oversees a robot used on part of the line.

The automation solution is completed by a wide variety of Allen-Bradley low-voltage products, including buttons, sensors and other accessories, inside the cabinets deployed at each station. Finally, the line’s safety infrastructure, which complies with all local safety legislation, comprises a number of Allen-Bradley safety gates, linked together with emergency stops at each station, all connected in series to safety relays within the main control cabinet.

Rockwell Automation Global Solutions Team Leader in The Czech Republic, Petr Veselý, explains: “I have worked with PHA for 10 years now.  For this project we met with their engineers, who gave us a very detailed specification, including 3D models of the final product. They also gave us their expectations regarding timings and volume targets. We delivered a complete solution – from the control architecture and software to supervision of the whole line, including all mechanical and electrical elements. We also dealt with three local mechanical assembly suppliers and once the concept had been created, we then handled all of the approvals within PHA.

“Once the mechanical design had been approved,” Veselý continues, “the manufacturing go-ahead was given and the electrical concept was developed. Upon approval, we employed four programmers from the Rockwell Automation office in Prague to create the software application. Two programmers worked on the main line and two on the inspection stations. Studio 5000® was used for visualisation and, in answer to one of PHA’s primary demands for flexibility, we applied customised application windows. Each station uses a separate all-in-one PC touch panel (18 on the main line and 11 in the standalone and test stations) running C++ applications. Further visualisation and control of the main conveyor is supplied by two Allen-Bradley PanelView Plus™ HMIs.

Results:

According to Novotny: “This successful project delivery demonstrates the professionalism and capabilities of our Global Solutions team, not only in the provision of technical solutions but also in the delivery of complete project management. The experience and skills obtained in this instance will be adopted as a basis for further similar opportunities in the automotive market, including future projects with PHA. Indeed, we are already in discussions with PHA for the provision of another door assembly for a different car model.”

Przemysław Sakowicz, Manufacturing Engineer at PHA Czech s.r.o. cites fast support, good relations and previous good experiences of working with Rockwell Automation as the primary reasons for using the leading automation provider again: “I know exactly what quality I can expect from Rockwell Automation, it has a very good team of programmers that reacts quickly to any issues or challenges we face. We had multiple customer audits before and during project start up and the auditors were very satisfied with what we have developed with Rockwell Automation, which is very important for us. I would particularly like to thank Petr Veselý and his team for the project fulfilment and management; they met all the requirements from my side.

“With regards to specific benefits of the Rockwell Automation solution,” Sakowicz concludes, “as well as hitting the production targets, we expect to see significantly reduced programming for the new line we are developing as well as the easy tuning and manipulation of the software we have seen in this solution. The Rockwell Automation Integrated Architecture has also delivered a more flexible and open platform for both remote troubleshooting and local maintenance.”

Written by Technical Lucidity on behalf of Rockwell Automation

Link to PDF (also created by Technical Lucidity Ltd.) EMEA2003 PHA Automotive (Lo)

Enhanced digital Andon production-issue-reporting solution delivers actionable data for better decision making at Toyota Motor Manufacturing (UK) Ltd.

Rockwell Automation Global Solutions in the UK designs and deploys new Digital Andon System at Toyota’s Burnaston plant to deliver real time and historic manufacturing data

Background: Toyota Motor Manufacturing (UK) Ltd. (TMUK) has two manufacturing plants in the UK employing over 3,200 people. Representing a total investment in excess of £2.2 billion, the vehicle manufacturing plant is located at Burnaston in Derbyshire and the engine manufacturing plant at Deeside in North Wales. The first car, a Carina E, drove off the Burnaston production line in 1992.

The Burnaston plant is the sole manufacturer of the Avensis model and the sole European manufacturer of the Auris and Auris Hybrid. The plant comprises a single assembly shop – which produces both models – and within this facility a number of information technology solutions are deployed to collate and deliver a wide variety of production management data.

These IT solutions are used as the communication framework for a number of production programmes and philosophies, which underpin Toyota’s impressive worldwide manufacturing efficiency reputation. One such programme is the company’s Andon solution, which allows line operators to call for management help or temporarily stop the production line if they spot something that they perceive could have a detrimental effect on vehicle quality. Originating from the word for a paper lantern, Andon – which in English translates to ‘sign’ or ‘signal’ – is a term that refers to an illuminated signal notifying others of a problem within the quality-control or production streams. It is a means of highlighting a problem as it occurs in order to immediately countermeasure the issue and prevent re-occurrence.

It was the intention of TMUK to refresh its current Andon systems through a phased programme of hardware and application replacement and modernisation. The approach would reengineer the existing organically developed solutions to provide a suite of integrated applications that could be deployed on a range of display technologies to leverage the data collected from shop floor programmable controllers.

For this upgrade project, Toyota appraised a number of technologies from different vendors and approached Rockwell Automation to develop the new solution based on more up-to-date and open technologies.

Challenge: The existing Line Andon System comprised a number of technologies from multiple vendors and included a reporting system that was also made up of a mixture of systems and software suites. The display technology was fairly basic. It had evolved from red and green bulbs that showed where the line had stopped, up to a more contemporary 640 x 720 LED-based solution that showed basic figures such as production targets. But this was beginning to show its age and was exhibiting failures.

TMUK needed to undergo a modernisation programme to develop a new solution that would not only collect all the necessary production information, but would also collate and decipher it before disbursing it in an easy to understand, actionable format to all parties involved in any remedial actions prompted by the Andon solution. The new solution was to be made up of three core elements: a Line Andon system; a Real Time Andon reporting system; and hourly reporting and shop display boards.

Solution: The new Digital Andon System (DAS) for TMUK is based on technologies already deployed, tested and delivered by the Rockwell Automation Global Solutions Team in North America team across multiple Toyota sites in the US.

The UK Global Solution team enhanced the DAS with the addition of FactoryTalk® Historian Site edition (SE) and clients to provide additional functionality that will deliver a standard Manufacturing Intelligence platform for Toyota to develop beyond the Andon solution, across its global manufacturing sites. Additional work for the UK project was undertaken by the Rockwell Automation Global Engineering Centre in India, which developed the graphical elements of the Line Andon system.

The Line Andon System is delivered by a number of stations (specific to each line) running FactoryTalk® View Station Site Edition (SE) on six physical PCs, but using video extender cables to connect to multiple monitors mounted above the line in full view of the operators and their supervisors. This system provides pull or line-stop indication to production line team leaders, giving them the ability to respond to team members’ concerns and avoid extended line stops. The new system gathers data from the line-control panels (LCP) for immediate reflection on local display screens as well as ensuring that data extracted from the LCPs is also made available for extraction, for use by the Real Time Andon and other systems.

The Real Time Andon System uses virtual servers for FactoryTalk Historian Site edition (SE) running in conjunction with RSLinx®, FactoryTalk® VantagePoint® and Microsoft SQL servers. Relevant information from these servers can then be displayed on various client PCs as web reports and on the large shop display boards that are located at strategic points around the assembly shop.

In operation, the Real Time Andon System gathers data from the shop floor controllers and then populates an SQL database. It can then display different levels of data graphically using a touchscreen interface, which provides supervisors with the ability to perform rapid identification of line stop or Andon pulls that are impacting production. The new system is a scalable, accessible integrated solution that will evolve with the production solution. In addition, the databases can also be used to calculate where potential issues may occur; and if there is any relationship to times, shifts or specific operator stations.

Completing the new installation are the new Shop Display Boards, which comprise a number of large-screen displays that summarise overall shop status and line-specific data, regarding planned volume, achievement and operation rate.

According to Alastair Moore, Section Manager Assembly Engineering at TMUK: “We had an idea of what we wanted to achieve in terms of modernisation, but our main focus was the visualisation. The main shop displays were 15 to 16 years old and really starting to show their age. We had a look at what was available from the market in terms of new solutions – including the most recent development of the incumbent hardware and software – and the solutions from Rockwell Automation were part of this mix. In the end, the final decision was based upon licensing costs and the way the whole solution ‘hung together’. Rockwell Automation was able to offer us something a lot more competitive.

“The majority of our existing production equipment is based on Rockwell Automation control solutions,” Moore continues, “so we already knew that Rockwell Automation could offer us a robust solution based on an Ethernet network; and the fact that its architecture is open and more technologically agnostic made it more attractive in the long term.”

The collection, collation, deciphering and delivery of pertinent actionable real-time manufacturing data is a core feature of the Rockwell Automation Connected Enterprise. The Connected Enterprise – an approach that leverages connected machines, supply chains and customers – allows companies to establish manufacturing processes that are information-rich, supported, more secure and ready for future market demands.

Ultimately, a Connected Enterprise approach creates a more competitive, innovative enterprise that can deliver insights to improve productivity, sustainability and economic performance through faster time to market, lower total cost of ownership, improved asset utilisation and enterprise risk management. Other benefits of access to real-time, contextualised information include minimised downtime, improved technology and process optimisation, greater workforce efficiency and smarter expenditure.

Results: TMUK now has a Digital Andon System that delivers exactly what it needs in terms of accurate, pertinent real-time operational information to both the line-side operators and their supervisors; speeding up the time taken to recover from a stop and to identify the root cause.

In addition, the Historian functionality gives them the ability to predict where problems may occur and take preventative action. Its open, integrated architecture and scalability also means that the hardware and software can be modified to suit future needs in terms of production volume or information requirements.

According to Guy Smithson, Account Manager UK Automotive & Tire at Rockwell Automation: “A similar Andon evolution took place in a Toyota plant in Kentucky USA and as well as sharing information to specific line supervisors, the information was more widely shared in order to discover how issues affected other operations in the production flow. In this instance the paint shop was able to react immediately to alerts generated by subsequent processes instead of waiting for a production report from the previous day. In addition to other Andon reporting streams, it was estimated that annual cost savings could be in the region of over half a million dollars. This whole new wider approach also addresses Toyota’s Muda philosophy, which tackles futility, uselessness and wastefulness.”

“The Rockwell Automation engineers are easy to work with,” Moore concludes, “and the mutual respect means that both sides are willing to listen to each other. Alan Williams (a senior engineer at Rockwell Automation UK) has been involved with Toyota for almost 20 years; we have known each other for a while and trust each other’s opinion.  We are looking to expand the system into other areas and factories and then potentially into other countries such as France, with any improvements and lessons learnt from these projects being rolled back to us.”

Written by Technical Lucidity on behalf of Rockwell Automation