Post on 26-Jul-2015
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
PUBLIC INFORMATION
Automotive supplier Quality System Modernization Drives 15 Percent Increase in OEE
Dana Mooers
Controls Engineer
This Global Tier One Automotive Manufacturer ranks among the world's leading automotive suppliers.
Products include automotive systems for vehicle control, braking, steering, suspension, and occupant safety, electronics, engine and other automotive components
One of it’s facilities in GA employs 200 employees and produces 4 million brakes per year for Ford F-250, F-350, F-450 trucks, Dodge Ram 1500, And Chrysler mini-vans and SUVs.
Twenty manufacturing lines each with multiple work cells containing up to eleven stations for brake assembly
◦ Brake component assembly in step process
◦ Quality measurement on established test values
◦ Pass or Fail based on essential quality metrics at each step
◦ Quality data capture at each step
Overall production performance was hampered by the need to manually manage quality metrics.
Accessing, maintaining, and upgrading the Quality System had became costly and difficult.
Quality reporting became more critical to meet customer-required real-time detail reports.
Legacy quality tracking software ◦ Proprietary code
◦ Maintenance and changes difficult and costly
◦ Lack of consolidation of data
◦ Data access difficult
Hardware ◦ Quality Control System hardware not networked
◦ Multiple standalone computers at each work cell
◦ Manual post-production metric data compilation
What was needed: ◦ Industry-standardized manufacturing intelligence
system
◦ Commercial-Off-The-Shelf (COTS) software that would not require extensive training to maintain
◦ Networked hardware across all manufacturing lines
◦ Scalable, reliable, and robust system
Create User Defined Requirements ◦ Individual user and stakeholder requirements
◦ Key Performance Indicators (KPIs)
◦ Various data sources
◦ Interfaces such as dashboards and HMIs
◦ Gaps in the infrastructure and technology
Designed a new architecture to deliver the stated objectives and goals
Scalable, Reliable, Robust
Software and database
Data concentrator Programmable Automation Controllers (PAC)
Pass/fail functionality using PACs
Automated centralized data collection
Real time on demand reports
Verification and Training
Comprehensive data capture across all thirteen of the twenty manufacturing cells
Performance metrics for all thirteen cells on an over-time or real-time basis
Quick identification of product or quality issues
Automated report distribution to users
50%
55%
60%
65%
70%
75%
80%
85%
90%
95%
100%
2013 2014
2015 (to date)
OEE
2013-2015 YOY OEE
62% 66% 76%
2015 Goal
•Full
Assembly
System
Integrate
•Machining
•Logistics
•Quality
Prove •Roll out to
division
plants
Roll-out
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