PEMSA: Automotive Paint Plant Unlocks Information, Gains Flexibility and Efficiency

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.

PUBLIC INFORMATION

PEMSA: Automotive Paint Plant Unlocks

Information, Gains Flexibility and Efficiency Complexity Project November 2013

2 Pintura y Ensambles de México, S.A de C.V..

Agenda

Project Objective

Scope

1. Hardware and Networks update

2. Software update

System process summary

Bedliner project above E-Coat

Benefits


Project Objective


Copyright © 2011 Rockwell Automation, Inc. All rights reserved. 4

MCP5

MCP3 MCP4

MCP1

2P500

MCP2

EMOS

MCP6

Scope


AVI PFCS

Historical

and

Production

DB

SPD receives Costumer Status, all status are available

Customer Ethernet

Production

Controllers

Ethernet PEMSA

Firewall

Router

Firewall

Router

SPD PEMSA

Data

information

collector

Scope (Cont.)


Status before Complexity Project


MCP 5

MCP 3

MCP 4

MCP 1

MCP 2

2P500

SQL Computer

Station

Control Room

EMOS

Control Room

EMOS

Smarteye

Smarteye Smarteye

Smarteye

Smarteye

Smarteye

Smarteye

Smarteye

Microsoft SQL

RSSqlTM

RSLinx®

VB Application

FTP Service

FTP Sap

Wonderware Intouch

RSLinx®

RSLogixTM 5000

MCP 6

Architecture before Complexity Project

8 Pintura y Ensambles de México, S.A de C.V.. Copyright © 2011 Rockwell Automation, Inc. All rights reserved. 8

MCP5

MCP3 MCP4

MCP1

2P500

MCP2

EMOS

MCP6

Ethernet topology before Complexity Project


Control

• Recipes data control in all production areas (Style-Option-

APA/APD-Color-Bed Liner).

• Exchange of data information between controllers assured.

Control

• Master Controller at EMOS Control Room was implemented to be able to modify styles to be processed and in line data change

required by production.

Control

• Integration of new device net bar codes.

• Pokayokes integration.

Control

• HMI visualization reconfiguration for new styles.

• Tracking of pick up boxes in all processes.

Control current status

10 Pintura y Ensambles de México, S.A de C.V.. Copyright © 2011 Rockwell Automation, Inc. All rights reserved. 10

MCP5

MCP3 MCP4

MCP1

2P500

MCP2

EMOS

MCP6

Current Topology


Infrastructure Server

VLAN MCPs VLAN Proc.

Control Room

EMOS

Control Room

EMOS Wonderware Intouch

RSLinx

RSLogix 5000

Co

ntr

ol

Ro

om

EM

OS

MCP5

Smarteye Smarteye Smarteye Smarteye Smarteye Smarteye Smarteye Smarteye

Smarteye

MCP2 MCP3 MCP6 2P500 MCP1 MCP4

FactoryTalk ®

Transaction Manager

Professional

Microsoft SQL Server

SAP – FTP Services

VantagePoint®

FactoryTalk® View Site

Edition StandAlone

COSTUMER

REMOTE

Master

Current Architecture


Configuration and clients

Data Base Services

Production Data

Base

Historical

Data Base

Applications

FactoryTalk

Transaction Manager VantagePoint

Data Services Control Technology

AB Controllers

FactoryTalk® Live

Data

AB Controllers

FactoryTalk View SE

Software solution


Complexity system view


Data information received from Customer: Do-all files in excel format are received twice every day. This Do-all file was modified or updated any time. SPD on line sequence delivery list from Costumer to deliver pick up

boxes. Production planning:

Was controlled from status G, to process the sequence delivery to the Costumer.

Production was divided in 4 blocks per day considering the current inventory status of boxes at process and in the finished product (PT) warehouse.

Logistics requested are critical requirements to production. There was not visualization of others status at costumer plant and

in the PEMSA process. Control Inventory Limitations.

Production management: Was based in the JIT .xls format program ,where logistics process

manually, the data received from Costumer and production planning.

Logistics status before Complexity Project


D7

E

E1 G

FB

F G1

G2

I

D2

D3

D4

B&W Delivery to

PEMSA

Delivery

Sequence

Delivery to

Costumer

Batch of 12 boxes

Batch of 12 boxes

Customer

Priorities

Sec a1

Sec a2

Sec

24 hrs from D2 to G1 9hrs PEMSA Production on sequence

Body

FRAME

Paint shop

Delivery

FINAL Line

Exit Final Line

Costumer Process (Before)


Logistics

•Direct communication system with the

customer that allows us to program and

deliver the units on time.

Logistics

•We collect information from the secondary

label and relate to primary label (cab) to

determine the characteristics of the box.

Logistics

•Status review of the cabs in our customer

facility to verify PEMSA adequate inventory.

Logistics Current Status


Logistics

•Scan the box label at the beginning of the

process (when it arrives to PEMSA).

Logistics

•Update the B&W inventory based in the box

characteristics.

Logistics

•Pick list are generated from the input boxes

(B&W) to feed the production line based on

priorities and availability, blocks of color and

B&W.

Logistics Current Status


D7

E

E1 G

FB

F G1

G2

I

D2

D3

D4

Shipment to

PEMSA B&W Sequence for

painting on PEMSA

Shipment to

Customer

Lote de 12 Unidades

12 Units Batch

Customer

Priorities

Sec a1

Sec a2

Sec

24 hrs From D2 to G2 9hrs PEMSA production on sequence

Body Pint TRIM

FINAL

Construction

Current Customer Process Flow


Planner


SPD System


Quality Graphics


Quality Production Report


Customer Status STAP

B&W Inventory

Status and Quantities, Traceability of the Process (E-coat, Primer, Color, Reworks,

Bedliner)

Quality (Reprocessing, SPOT, Rescue)

Finish Product Inventory

PEMSA Shipment

System Process Summary


Bedliner Project above E-Coat


Reducing finished goods inventory by 50%.

70% increase in production efficiency. Better communication with our customers.

B&W Real Inventory. Problems like robot crashes, unpainted boxes, etc are gone. These type of problems could cost between 30 min to 1 hour stop production (30 boxes per hour aprox).


PEMSA production is based on the customers real needs (size and colors).

Avoid the shipment of units with a wrong color to our end customer.

Better communication in our whole plant (Production, Logistics, Maintenance, etc.).

Easier integration of new products with a most robust system.

Primer, Base and Clear consumption was decreased by 45% in bedliner boxes.


Thank you! ¡Gracias!


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PEMSA: Automotive Paint Plant Unlocks Information, Gains Flexibility and Efficiency

Technology

Transcript of PEMSA: Automotive Paint Plant Unlocks Information, Gains Flexibility and Efficiency