Rockwell Automation Solution Typical Features

As the global economy becomes more and more deepening of the integration process, national auto industry more competitive international, China's auto industry is also facing challenges, "WTO", car manufacturers are facing increased production in addition to the whole car, reduce production A number of challenges, such as cost. Therefore, by adopting internationally advanced management ideas, modern management methods have become a top priority. In general, some of the specific problems automakers face in logistics include:

The call of existing material and the mode of pulling material can not meet the problem of precise distribution of materials on the line side in the collinear production process of various large-scale models. Existing material escort mode is inefficient and wastes a lot of human resources.

production material requirements can not accurately capture real-time, real-time will not achieve the next parts production plans and supplier parts supply, resulting in materials backlog inventory escort or not timely resulting in waste and cost of production plus an unnecessary whole.

Real-time consumption of the line-side materials can not be accurately grasped, the management mode of the material distribution is delayed, and the management efficiency is low. The level of materials management in place is behind schedule.

For long-term recording of production information, quality information, etc., and the historical traceability of the main loading materials, it is impossible to establish a factory tracking for the quality of the single-body assembly.

In combination with these requirements, Rockwell Automation has successfully developed and implemented a variety of logistics solutions for automotive manufacturing processes in conjunction with its national engineering partners, including:

ANDON material real-time traction system

EPS / PPS electronic production system

KAN Kanban Management System

All of these solutions should be based on the different manufacturing scales, different manufacturing processes and different management models of each automobile manufacturer to determine which solution to use and how to implement it. The implementation methods and main functions of these systems will be described one by one in the following sections.

ANDON material real-time pull system solution function introduction

The ANDON system was originally developed by Toyota Motor in Japan. It is primarily used to perform visual management of the workshop location, thereby improving the level of workshop management. ANDON the material system is mainly developed based on the ANDON system, next to the factory floor by the production facility of a number of stations to request a material call button, from the material store and the factory floor information display In the material request request, the PC software system will record the time, location and material response of each material request in real time and record and analyze for a long time period.

For these types of stations of materials more stations the call can be provided a touch screen material, since each material can be a touch screen according to the calling unit and the plurality of materials different call picture models, each image, but also a plurality of materials Trigger button for material drive. Therefore, it is only necessary to set up some material touch-screen displays on each of the major assembly lines and sub-assembly lines to perform the material call function.

This material is provided in the logistics display area, the main object is achieved by a large real-time distribution panel display of information materials; station store floor material station floor; job programming information search vehicles. The display of material information will be used as a complement to the material display monitoring and to the bill of material printing system in the material area. In the case of material delivery personnel and forklift truck drivers in the logistics area, the large screen system can be used to observe the current production status of production materials and station in the workshop. At the same time, you can easily know the responsibilities of your next position and other material distribution employees.

PPS Production Draw System Solution Function Introduction

PPS

Rockwell Automation Automotive Automation Information System Solution

Rockwell Automation Solution Typical Features

As the global economy becomes more and more deepening of the integration process, national auto industry more competitive international, China's auto industry is also facing challenges, "WTO", car manufacturers are facing increased production in addition to the whole car, reduce production A number of challenges, such as cost. Therefore, by adopting internationally advanced management ideas, modern management methods have become a top priority. In general, some of the specific problems automakers face in logistics include:

The call of existing material and the mode of pulling material can not meet the problem of precise distribution of materials on the line side in the collinear production process of various large-scale models. Existing material escort mode is inefficient and wastes a lot of human resources.

production material requirements can not accurately capture real-time, real-time will not achieve the next parts production plans and supplier parts supply, resulting in materials backlog inventory escort or not timely resulting in waste and cost of production plus an unnecessary whole.

Real-time consumption of the line-side materials can not be accurately grasped, the management mode of the material distribution is delayed, and the management efficiency is low. The level of materials management in place is behind schedule.

For long-term recording of production information, quality information, etc., and the historical traceability of the main loading materials, it is impossible to establish a factory tracking for the quality of the single-body assembly.

In combination with these requirements, Rockwell Automation has successfully developed and implemented a variety of logistics solutions for automotive manufacturing processes in conjunction with its national engineering partners, including:

ANDON material real-time traction system

EPS / PPS electronic production system

KAN Kanban Management System

All of these solutions should be based on the different manufacturing scales, different manufacturing processes and different management models of each automobile manufacturer to determine which solution to use and how to implement it. The implementation methods and main functions of these systems will be described one by one in the following sections.

ANDON material real-time pull system solution function introduction

The ANDON system was originally developed by Toyota Motor in Japan. It is primarily used to perform visual management of the workshop location, thereby improving the level of workshop management. ANDON the material system is mainly developed based on the ANDON system, next to the factory floor by the production facility of a number of stations to request a material call button, from the material store and the factory floor information display In the material request request, the PC software system will record the time, location and material response of each material request in real time and record and analyze for a long time period.

For these types of stations of materials more stations the call can be provided a touch screen material, since each material can be a touch screen according to the calling unit and the plurality of materials different call picture models, each image, but also a plurality of materials Trigger button for material drive. Therefore, it is only necessary to set up some material touch-screen displays on each of the major assembly lines and sub-assembly lines to perform the material call function.

This material is provided in the logistics display area, the main object is achieved by a large real-time distribution panel display of information materials; station store floor material station floor; job programming information search vehicles. The display of material information will be used as a complement to the material display monitoring and to the bill of material printing system in the material area. In the case of material delivery personnel and forklift truck drivers in the logistics area, the large screen system can be used to observe the current production status of production materials and station in the workshop. At the same time, you can easily know the responsibilities of your next position and other material distribution employees.

PPS Production Draw System Solution Function Introduction

PPS...

is the English Pull Production System, translated into Chinese is the production system pulled, which mainly integrates the Rockwell Automation Contrologix system platform, multi-phase technology RSNetLinx new integrated communication network architecture, IBM industry ABI software platform automotive An automated information system that is specifically requested and pulled by real-time materials for automotive manufacturing companies in the automotive manufacturing process. The system consists mainly of three basic modules: basic data, vehicle tracking and material consumption. PPS system will be used to pull plant material in real time; each of the vendor components stimulating production in real time; consumption of plant material and statistics; the main components with body tracking and other functions.

The main functions of the PPS system include:

Material report function

Material Consumption Report

Analysis of staff performance

Vendor evaluation report (including on-time delivery, accuracy, quality issues, etc.)

Recording analysis, reproducing the entire process of pulling, providing decision data (details of the registration of various aspects of the process the material comprises a request time, the requested time of confirmation, to draw time, request information, materials, etc.) to further optimize the operation

Query and material stock report from the line library

The store buffers library for the line-side library transfer register query generates the store material buffer library for the line-side library transfer database report

Counting report

Row Library Library Query and Report

Vehicle tracking function

Inventory Management Function

Stock count function

Daily operation function

The main structure of the system is shown below:

As can be seen in the figure above, IBM's ABI software platform and Rockwell Automation's Contrologix control system will be the core of the factory floor control equipment and the core of the superior software platform. The ControLogix controller will control the scanning and identification equipment on the shop floor and will collect the body's movement information in real time. This body information will be transmitted to the IBM ABI system platform software in real time. The ABI platform software will automatically calculate the required amount of materials based on this body information and will automatically calculate the consumption of the materials on the line side. The wireless touchscreen forklift truck sends commands from forklifts in real time. The system process is as follows:

The entire PPS system runs on the Windows system platform. All program modules are distributed and each functional module supports standard WEB-based display and operation functions. The figure below shows the distribution of the structure of the system function.

EPS / PPS Production Pull System Solution Function Introduction

Kanban material traction material call system, is a more traditional and very effective way to transfer material, is widely used in many domestic and foreign automobile logistics system manufacturers; This material is mainly used in common parts methods and call transfer materials Small pieces.

Kanban Material Definition: Kanban Material is a plastic or paper material card The material name, material number, material quantity per carton and carton number are recorded on the carton. Sometimes a bar code that uniquely identifies the material is printed on the material's kanban. Kanban material is usually designed and produced by the auto parts logistics department according to the type of material and the actual number of work units.

Material distribution process

The material parts supplied by the supplier are also placed on the material kanban card at the same time as the unpacking and refilling classification of the material delivery container. A material card is placed in each box (or other container unit).

After the material is sent to the assembly station, when the operator prepares to use the first material of the container, the material card is first placed in the material carton collection box near the station.

materials sector will have the person responsible in the sound system and ANDON alarm ready, periodic workshop on the site in each collection materials Kanban tank inspections are carried out, when a Kanban Kanban material found in the collection box hit um pre-determined number (on behalf of species) The kanban card of material will be collected back into the logistics area and fed according to the information on the card.

For larger materials such as: windshield materials, benches, tires and other materials next to parts in the factory floor storage station can not be a lot of (frequent delivery) the use of material or sensitive screen materials to touch call button, set the material in the call logistic area The alarm display method is used to perform the material distribution.

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