Core systems of vehicle manufacturing
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Transcript of Core systems of vehicle manufacturing
Core Systems
System Functions
ERP Material info, management of Order/Purchase/Sales
MES Scheduling, Broadcast, Process parameters, PLC interface, Upstream/Downstream interfaces, Cycle time management
WMS Management of Storage, Import/Export, Delivery
PLM EBOM, MBOM, Error Proofing BOM, Kitting BOM
Call system Auto Call, Manual Call
Kitting Kitting operation
Error Proofing Error Proofing of Part Picking, Tooling, Dimension
Quality Management Defect, Short Build, Over Build, Quality Gate
Traceability Traceability of Batch, S/N, Uniqueness. Genealogy
Andon Stop, Error, Material, Quality
Kanban Plan, WIP, Equipment, Defect
SOP Approval, Revision, Display
PLM
MBOM EP BOMKitting BOM
ERP
Sales OrderWork Order
Shipping Order
MaterialPurchase
Order
WMS
Import ExportStorageDelivery
Call System
Auto Call Manual Call
Kitting
Kitting Rack EP
Error Proofing
Rack EP Locationing Tool EP
Quality
Defect Short BuildQuality
Gate
Andon
Equipment Andon
Material Andon
Stop Andon
Kanban
Plan WIP Equipment Defect
SOP系统
流程审核 版本控制 SOP显示
Traceability
Batch UniqueS/N
MES
Order resequence
Process Parameters
Upstream Interface
PLC interface Status inquiry
Broadcast
Cycle Management
Assembly
PLC
Equipment
Core DataFlow
Flexible MFG-Order and Process Parameters
• ERP downloads Orders and Configurations into MES.
• MES adds Order Status, Quality Status, Process Parameters, and downloads them into PLC.
• According to MES-PLC protocol, PLC turns Process Parameters into control commands, or program id.
• Robots or Equipment operate accordingly, and them upload process data and result into MES.
• MES runs business logic accordingly, and them to update Order Status, Quality Status, and broadcast into ERP and other systems.
• The whole process can be running in the background automatically.
Robots
PLC
ERP
OrderConfigura
tion
MES
Order Configuration
StatusProcess
Parameters
TestingEquipmentManufacturing
Equipment
Control Commands
TestData
ProcessData
MES-PLC Handshaking exampleSender Receiver TagMES PLC With PLC Mode 0
MES PLC In Position Received 3
MES PLC Process Parameters 4
MES PLC Error Proofing Sent 5
MES PLC MES Completed 10
PLC MES Auto Mode 0
PLC MES Vehicle Number 1
PLC MES In Position 2
PLC MES Error Proofing Received 6
PLC MES Process Data 7
PLC MES Error Proofing Completed 8
PLC MES PLC Completed 9
PLC MES Release Vehicle 11
Cycle Starts Assembling Cycle Ends
Error Proofing• PLM downloads BOM into MES.
• MES assigns Rack IDs or Tool IDs into Parts for specific station, which is EP BOM.
• MES downloads EP BOM into PLC.
• PLC turns on Rack lamp, or enables Tool according to EP BOM.
• PLC uploads EP finish signal into MES, as step of MES-PLC handshaking.
PLM
MBOM
MES
Part Error Proofing
Tool Error Proofing
Turn On Rack Lamp
Enable Tool
EP finishEP finish
Material Flow-Call/Kitting/Delivery/Assembly
• When product passes through trigger station, MES broadcast data into Call system automatically.
• Or Operator press Andon button manually.
• Call system forwards message into Kitting system.
• Kitting and upload material location into WMS.
• WMS informs delivery team to transfer parts into assembly station.
Auto Call
Delivery
Kitting
Assembly Station
MES
Broadcast
PLM
Kitting BOM
Manual Call
Trigger Station
Material Andon
WMS
Delivery
KittingSystem
Call System
Put into assembly
Inspection
Testing
Quality Gate
Quality System
Defects
Quality StatusRepair
MES
Order Status
Quality Status
DefectS?
Test Failure?
Scrap/Hold?
Short Build?
Next Process
Missed Station?
PLC
Turn Table
Closed-Loop Quality Control
• In assembly stations, operators can input Defects during inspection.
• In testing statins, Equipment collect test data and result.
• Quality system sync Quality Status into MES.
• MES sync Order Status(e.g. Scrap/Hold) into Quality System.
• Quality Gates check Defects, Testing, Scrap, Hold, Short Build, Missing Stations, and generate Quality Gate reports, and then sync Quality Status into MES, and MES sends control command into PLC, according combination of Order Status and Quality Status.
Cycle Time Calculation
Index Time
Previous Product Leaves
= Next Product Schedule Time- Previous Product Leave Time
Starved Time
=Next Product Arrive Time-Previous Product Leave Time-Index Time
Standard Cycle Time
Configured Cycle Time
Allowed Cycle Time
ExceptionalCycle Time
Assembly Start
Blocked Time
ProductLeave
AssemblyEnd
Actual Assembly Time=Assembly End Time-Assembly Start Time
Overall Time=Current Product Leave Time-Previous Product Leave Time
Configured Cycle Time over Standard Cycle Time
=Assembly Time-Standard Cycle Time-Allowed Cycle Time
=Actual Leave Time-Assembly End Time
Thank You!
