Sequence Modes Document - ps.nafta.extra.fcagroup.com

Introduction ……………………………………………………………………….……1

Important Acronyms, Terminology and Definitions ...……….……………….3-5

Plant Floor Station Familiarization ………………………..……………………..5-7

Modes of Sequencing Available in a NON-QAS Assembly Plant ..…………..8

NON-QAS - T* Mode (NON-ALS) …………………………………………..9-10

NON-QAS - TF Mode (NON-ALS) …………………………………….…...11-12

NON-QAS - TX Mode (NON-ALS) ………………………………………...13-14

NON-QAS - W* Mode (NON-ALS) ………………………………………...15-16

NON-QAS - M* Mode (NON-ALS) ………………………………………...17-18

NON-QAS - R* Mode (NON-ALS) ………………………………………....19-20

NON-QAS - B* Mode (NON-ALS) ………………………………………....21-22

Modes of Sequencing Available in a QAS 1st Generation Assembly Plant ..23

QAS 1st - T* Mode (ALS) …………………………………………………...24-25

QAS 1st - TF Mode (ALS) …………………………………………………...26-27

QAS 1st - TX Mode (ALS) …………………………………………………..28-30

QAS 1st - A* Mode (NON-ALS) ….………………………………………...31-32

QAS 1st - A* Mode (ALS) …………………………………………………..33-34

QAS 1st - W* Mode (ALS) ………………………………………………….35-36

QAS 1st - B* Mode (ALS) …………………………………………………..37-38

Modes of Sequencing Available in a QAS 2nd

Generation Assembly Plant..39

QAS 2nd

- PM Mode (NON-ALS) ……………………………….…………..40-41

QAS 2nd

- PM Mode (ALS) ……..……………………………….…………..42-44

QAS 2nd

– W* Mode (NON-ALS) ……………………………….………….45-46

QAS 2nd

– W* Mode (ALS) …………….……………………….…………..47-49

Appendix ……...………………………………..………………………………….…..50

1

This document is geared towards explaining the different modes of sequencing –

process of monitoring plant floor devices (PFD) and advancing vehicle track sequence

numbers used in different Chrysler plants.

The following Questions/Answers will provide insight as to the purpose of this

document:

Q. Why are modes of sequencing needed?

A. In order to keep track of vehicles, Track Sequence Numbers (TSN) are assigned to

vehicles, which are operated on in order of their numbers. Therefore a process of

advancing these TSN numbers is required

Q. Why are there different modes of sequencing as opposed to just one mode?

A. Every plant differs in their production process. Therefore PFCS came up with

different modes to suit the common plant needs.

2

THIS PAGE INTENTIONALLY LEFT BLANK

3

IMPORTANT ACRONYMS & TERMINOLOGY

PFCS – Plant Floor Communication Systems

PFD – Plant Floor Device

PFS – Performance Feedback Systems

ALS – Automatic Line Stop

QAS – Quality Alert Systems

BC – Broadcast

PES – Process Equipment Setup (Subsystem of Broadcast)

TSN – Track Sequence Number

VIN – Vehicle Identification Number

RUNDOWN – Bolt Operation

SPINDLE – Torque Tool

SALES CODE – This is a code assigned by the Vehicle Order Processing unit (VOP)

when order for a vehicle is placed

KEYBOARD ENTRIES related to PFS:

• PF4 – Go back to previous vehicle

• PF5 – Go forward to next vehicle

• PF2 – Start the line

• PF9 – Bypass the current unit and go to next vehicle

• Enter - Enter

FREQUENCIES for MPFB screen:

• 001 – On Enter, go to next sequence

• 999 – On Enter, do not go to next sequence

• 0001 – Advance only when a scan a received

• 998 – On Enter, go to next sequence and send PFCS a ‘Next’ advance

message

1 For scanning purposes only

4

To gain further insight as to why sequence modes are needed, a brief explanation of what

the Performance Feedback System, PFS, does is needed.

PFS – This is an on-line data management and reporting system that helps

prevent the shipping of vehicles which have open problems through an

alliance with BROADCAST.

Therefore, in order for PFS to obtain information on the status of operations

performed on vehicles, PFDs have to be able to relate this information to PFS.

Hence, PFCS, which acts as a communication link between PFDs and PFS, has come

up with various ways to communicate with these devices and sequence the VINs as

suited to each plant needs.

Plant Floor Devices, PFDs, are of two types: Process Equipment and Torque Monitoring

Equipment. The different modes of sequencing are generally concerned with the Torque

Monitoring Equipment. Torque monitoring is performed on Single Spindle Nut Runner

Tool and Multi Spindle Nut Runner Tools.

Single Spindle Nut Runner Tool: This is used in single and multi bolt operations, with

or without End-Of-Cycle (EOC) button.

- For a Single Spindle/Single Bolt station, a Single Spindle Nut Runner Tool is

used to perform a single rundown

- For a Single Spindle/Multi Bolt station, a Single Spindle Nut Runner Tool is

used to perform multiple rundowns

Multi Spindle Nut Runner Tool: This is used in multi bolt operations, with or without

End-Of-Cycle (EOC) buttons. The rundowns are done simultaneously.

- For a Multi Spindle/Multi Bolt, a Multi Spindle Nut Runner is used to

perform a single set of rundowns

5

PFS

Terminal

TorqueMonitor

TerminalServer

PFCS

PFS

PLANT FLOOR STATION FAMILIARIZATION

Figure 1 shows a simple torque

monitoring setup depicting the

communication flow from a simple

in-station torque device to PFS.

FIGURE 1: Standard Torque Monitoring Setup

The figure below represents a typical plant station where an operation is performed on a

vehicle2.

FIGURE 2: Typical Station in a Production Line

2 Figure 2 will be referred to throughout the rest of this document.

20 ft.

JOB SPACE

PFS

TERMINAL

TORQUE

TOOLLIMIT

SWITCHOPERATOR

6

A plant floor device (PFD) in a plant station, before initial use, is setup using a PFS

application. This is done by assigning different parameters to appropriate fields of the

PFS application – QUNX. The figure below is a screen shot of the QUNX screen

showing the different fields required for a PFD setup.

FIGURE 3: PFS QUNX Setup Screen for PFDs

Most of the fields in the QUNX screen (figure 3) are PFCS related fields and will be

briefly touched upon.

If ‘DOWNLOAD INFO TO PFCS’ from figure 3 above is set to ‘Y’, then the setup

information for the ‘PFCS MACHINE ID’ will be sent to PFCS.

If ‘QAS LINESTOP’ is set to ‘Y’, ALS MODE is active and the Pass/Fail message is

sent to the QAS system as well as torque results to PFS. For this case, QAS has the

ability to stop the production line on torque failures. If ‘QAS LINESTOP’ is set to ‘N’,

then torque results are sent only to PFS; this is referred to as the TORQUE

MONITORING MODE.

‘STATION ID’, and ‘LINE SEGMENT ID’ are for QAS related modes. ‘STATION

ID’ is used to identify workstations while ‘LINE SEGMENT ID’ is for ALS specific

modes.

‘NUMBER OF TOOLS’, ‘PLC ID’, and ‘OPERATION MODE’ are also ALS

specific fields. ‘NUMBER OF TOOLS’ indicates the number of tools assigned to a PFS

terminal.

‘OPERATION MODE’ offers four sub modes:

7

Production Mode3 (P) – The line stops on failures and missed operation.

Training Mode (T) – This mode enunciates failures but does not stop the line.

Launch Mode (L) – The line stops on failure only.

Disable Mode (D) – The line is disabled.

‘SEQUENCE CONTROL’ is used to input the sequence mode to be performed in that

station. That is, this field determines if the sequence mode for the station is T*, A*, M*,

W* etc.

‘OPERATION CODE’ relates to the sales code formula defined in the Process

Equipment Setup (PES) of BROADCAST (BC); PFCS obtains it as part of a status move

download from BC. Operation code is used an index to a location in BC data to

determine whether an operation should be performed on a vehicle or not. An

‘OPERATION CODE’ with a value indicates that the tool is sales code dependent.

Operation Codes and their meanings

OPERATION CODE RANGE MEANING

0000 – 0000 Operation is to be performed on every unit

0001 – 0100 Tool is sales code dependent and the bolt count is

determined from the QUNX screen

3001 – 3100 Tool is sales code dependent and the bolt count is

dynamically determined from values at index of the

given Operation Code in BC data

3 ‘OPERATION MODE’ is usually set to this sub mode.

8

MODES OF SEQUENCING AVAILABLE IN A NON-QAS

ASSEMBLY PLANT

This section of the document will elucidate the sequences of operations and the different

modes of sequencing available in a plant where QAS is either not active for the station or

present in the plant. In this environment, the torque results are sent directly to PFS

through PFCS; this is commonly referred to as the TORQUE MONITORING MODE

or the NON-ALS MODE.

In a typical NON-QAS assembly plant, the sequences of operations in a production line

are as follows:

SEQUENCES OF OPERATIONS

1. The plant floor operator verifies that the system is ‘in synch’ with the floor by

matching the Track Sequence Number (TSN) shown on vehicle’s build sheet to the

TSN shown on the PFS screen.

2. The operator performs the required torque operation for the TSN on the vehicle

3. The operator signals the end of cycle using the appropriate EOC button on the tool or

the PFD controller sends the rundown data automatically to PFCS.

4. PFCS sends the torque results to PFS and advances to the next TSN.

5. PFS receives the next TSN to be operated on from PFCS.

9

T* - Stands for tool sequencing. The TSN is advanced when PFCS determines the

overall pass record. If there is a torque failure, the TSN will not be advanced and the

operator gets a chance to ‘FIX’ the problem in station. In T* mode, the sequence of

operation is as follows:

1. PFS screen shows TSN of vehicle to be operated on as it enters the station

If the station is setup for a Single Spindle/Single Bolt operation,

2. The operator performs the rundown and the Tool Controller sends the result to

PFCS

If the torque result is a ‘fail’,

i. PFCS will not advance the TSN but will send the ‘failed

message’ to PFS and the operator gets a chance to fix the

problem

If the torque result is a ‘pass’,

i. PFCS will advance to the next TSN, which will be sent to

PFS, along with the torque result

If the station is setup for a Single Spindle/Multi Bolt operation,

2. The operator performs the rundowns which are sent to PFCS as each rundown

is completed

If the torque result of an individual rundown is a ‘fail’,

i. PFCS will send the result to PFS and the operator will try

to correct the failed rundown

If the torque result of an individual rundown is a ‘pass’,

i. PFCS will not send the results to PFS until it has collected

the required number of passed rundowns

ii. On the last passed rundown, PFCS will set the overall

Pass/Failed flag to ‘P’ and will advance to the next TSN

iii. PFCS sends all the rundowns to PFS in a single packet of

data along with the TSN

If the station is setup for a Multi Spindle/Multi Bolt operation,

2. The operator performs the required number of rundowns and the Tool

Controller sends the result to PFCS


i. PFCS will not advance the TSN but will send the ‘failed

message’ to PFS and the operator gets a chance to fix the

problem


i. PFCS will advance to the next TSN, which will be sent to

PFS, along with the torque result

NON-QAS – T* MODE (NON-ALS)

10

For the above operations, PFCS or the Tool Controller can determine the overall

Pass/Fail and then send the overall results to PFCS. Below, is a flow chart of T* mode.

FIGURE 4: Process Flow for a NON-ALS Station using T* Mode

T* MODE (NON-ALS)

PERFORM/REPEAT

RUNDOWN

IS IT A PASS

OR FAIL?

SEND

RESULTS TO

PFCS

pass

HAVE ALL

OPERATIONS BEEN

COMPLETED

SUCCESSFULLY?

no

yes

fail

VEHICLE ENTERS

STATION

PFCS SENDS

RESULTS AND

NEXT TSN TO PFS

SEND 'FAIL' TO

PFS

NON-QAS – T* MODE (NON-ALS)

11

TF – Tool sequence on overall PASS or FAIL. The TSN is advanced when PFCS

receives a pass or fail record from the tool controller. This mode is not widely used

except in a couple of plants because most tool failures could be fixed in station. This

mode is closely related to T* except in advancement of TSN even on torque failures. The

sequence of operation is as follows:




PFCS

If torque result is a ‘pass’ or ‘fail’,

i. PFCS forwards the torque result with the next TSN to PFS


2. The operator performs the rundowns, which are sent to PFCS as each

rundown is completed

If the torque result of an individual rundown is a ‘pass’ or ‘fail’,


the required number of rundowns that have passed or failed

for that operation

ii. PFCS sets overall Pass/Fail flag in accordance with the

number of Passes/Fails for individual tools

iii. PFCS forwards the tool results with the next TSN to PFS



PFCS

If the torque result is a ‘pass’ or ‘fail’,

i. PFCS sets overall Pass/Fail flag in accordance with the


ii. PFCS forwards the tool results with the next TSN to PFS

NON-QAS – TF MODE (NON-ALS)

12

Below is a flow chart representation of the process of operations using TF mode.

FIGURE 5: Process Flow for a NON-ALS Station using TF Mode

TF MODE (NON-ALS)

PERFORM

RUNDOWN

IS IT A PASS

OR FAIL?

HAVE ALL

RUNDOWNS BEEN

COMPLETED?

SEND RESULTS

TO PFCS

pass

yes

no

VEHICLE ENTERS

STATION

SEND RESULTS

TO PFS

fail

PFCS SENDS

RESULTS AND

NEXT TSN TO PFS

NON-QAS – TF MODE (NON-ALS)

13

TX - This a tool sequence mode where more than one track number is sequenced. ‘X’

represents integers from 2 to 9. The TSN is advanced automatically by ‘X-1’ when PFCS

determines an overall pass record. For example, if a station in a plant set to T2, then the

operator works on alternate vehicles. On a torque failure, the screen will not advance and

the operator gets a chance to ‘FIX’ the problem in station. This mode differs from T*

only in the number of vehicles that get advanced at a time4. In TX mode, the sequence of

operation is as follows:




PFCS


i. PFCS will not advance the TSN but will send the result to

PFS and the operator gets a chance to fix the problem


i. PFCS will advance the TSN by ‘X-1’ and will send it,

along with the torque result, to PFS



is completed






the required number of passed rundowns


Pass/Failed flag to ‘P’ and will advance to the next TSN by

‘X-1’




3. The operator performs the required number of rundowns and the Tool

Controller sets overall Pass/Fail and sends the result to PFCS


i. PFCS will not advance the TSN but will send the result to PFS

and the operator gets a chance to fix the problem

4 Note: If X = 1, TX mode will be the same as T* mode.

NON-QAS – TX MODE (NON-ALS)

14


ii. PFCS will advance the TSN by ‘X-1’ and will send it,

along with the result, to PFS

In this mode, PFCS or the Tool Controller could determine the overall PASS or

FAIL. The flow chart for the process of operations is shown in Figure 6.

FIGURE 6: Process Flow for a NON-ALS Station using TX Mode

PFCS SENDS

RESULTS AND TSN

TO PFS

TX MODE (NON-ALS)

PERFORM/REPEAT

RUNDOWN

IS IT A PASS

OR FAIL?

SEND

RESULTS TO

PFCS

pass

HAVE ALL

RUNDOWNS BEEN

COMPLETED

SUCCESSFULLY?

no

SEND TO PFS

VEHICLE ENTERS

STATION

fail

PFCS ADVANCES

TO TSN BY 'X-1'

UNITS

yes

NON-QAS – TX MODE (NON-ALS)

15

W* - This is a manual sequence mode that displays next TSN when an operator hits a

keyboard function key. On a torque failure, the operator gets a chance to ‘FIX’ the

problem in station. This mode requires the use of MPFB frequencies5. To manually

sequence the TSN, the operator could:

a. Hit the Enter Key if the MPFB frequency is set at 001 or 998

b. Hit the PF4 Key, scan or manually type the TSN if the MPFB frequency is set at 999

In W* mode, the sequence of operation is as follows:

1. The operator sequences to next vehicle entering the station on PFS terminal


2. The operator performs the rundown and the Tool Controller sends the result

to PFCS


i. PFCS will send the torque result to PFS and the operator

gets a chance to fix the problem in station


i. PFCS forwards the torque result to PFS

ii. The operator hits a predefined function key in order

to sequence

iii. PFCS sends the next TSN to PFS


2. The operator performs the rundowns which are sent to PFCS as each


If the torque result of a rundown is a ‘fail’,


to correct the failed rundown in station

If the torque result of a rundown is a ‘pass’,

i. PFCS will send the result to PFS when it has collected the

required number of rundowns

ii. All subsequent rundowns are dropped until sequenced

iii. PFCS sends next TSN to PFS when operator hits a

predefined function key



PFCS


i. PFCS will send the torque result to PFS and the operator

gets a chance to fix the problem in station

5 Please refer to Page 2 of this document for the different types of frequencies and how they affect PFCS

NON-QAS – W* MODE (NON-ALS)

16


i. PFCS sends the torque result to PFS

ii. The operator hits a predefined function key in order

to sequence


Below, is a flow chart representation of the process of operations using W* mode.

FIGURE 7: Process Flow for a NON-ALS Station using W* mode

PERFORM/REPEAT

RUNDOWN

IS IT A PASS

OR FAIL?

SEND

RESULTS TO

PFCS

HAS OPERATOR

MANUALLY

SEQUENCED?

PFCS SENDS

NEXT TSN TO

PFS

W* MODE (NON-ALS)

HAVE ALL

RUNDOWNS BEEN

COMPLETED

SUCCESSFULLY?

pass

PFS FUNCTIONKEY

yes

SEND TO PFS

fail

no

SEND

RESULTS TO

PFS

yes

VEHICLE ENTERS

STATION

no

NON-QAS – W* MODE (NON-ALS)

17

M* - 6This mode’s operation is very similar to W* with very few differences; the method

of sequencing is the same for both modes. This mode requires the use of MPFB

frequencies7. To manually sequence the TSN, an operator could:

a. Hit the Enter Key if MPFB frequency is set at 001 or 998


The sequence of operation for M* is as follows:


If the station is setup for Single Spindle/Single Bolt operation,


to PFCS


i. PFCS will send the fail result to the PFS and the operator

gets a chance to fix the problem


i. The operator hits a predefined function key in order to

sequence

ii. PFCS will send the torque results and the next TSN to PFS

If the station is setup for Single Spindle/Multi Bolt operation,







i. PFCS will collect and store the required number of

rundowns

ii. All subsequent rundowns are collected until sequenced

iii. PFCS sends the torque results and the next TSN when the

operator hits a predefined function key

If station is setup for Multi Spindle/Multi Bolt operation,


PFCS


i. PFCS will send the fail result to PFS and the operator gets a

chance to fix the problem

6 M* is rarely chosen in ALS MODE

7 Please refer to Page 2 of this document for the different types of frequencies and their implications

NON-QAS – M* MODE (NON-ALS)

18


i. The operator hits a predefined function key in order to

sequence

ii. PFCS will send the torque results and the next TSN to PFS

FIGURE 8: Process Flow for a NON-ALS Station using M* mode

PERFORM/REPEAT

RUNDOWN

IS IT A PASS

OR FAIL?

SEND

RESULTS TO

PFCS

HAS OPERATOR

MANUALLY

SEQUENCED?

PFCS SENDS

NEXT TSN TO

PFS

M* MODE (NON-ALS)

HAVE ALL

RUNDOWNS BEEN

COMPLETED

SUCCESSFULLY?

pass

PFS FUNCTIONKEY

SEND TO PFS

failno

SEND

RESULTS TO

PFS

yes

VEHICLE ENTERS

STATION

yes

no

NON-QAS – M* MODE (NON-ALS)

19

R* - This mode of sequencing is similar to T* except that PFCS advances to the next

Operation-Required TSN, skipping up to ten NO-OP track sequence numbers. This

option is chosen only for Torque Monitoring mode i.e. NON_ALS mode. This mode is

useful when a particular operation, at a station, is not performed on every unit, especially

if the number of units to skip is not consistent. The sequence of operation is as follows:




to PFCS


i. PFS will send the ‘fail result’ to PFS and the operator gets a



i. PFS will advance to the next operation-required TSN,

which it will send to PFS, along with the torque result



is completed






the required number of rundowns, that have pass results,

for that operation


Pass/Fail flag to ‘P’ and will advance to the next operation-

required TSN



If the station is setup for Multi Spindle/Multi Bolt operation,


PFCS


i. PFS will send the ‘fail result’ to PFS and the operator gets a


NON-QAS – R* MODE (NON-ALS)

20


i. PFCS will advance to the next operation-required TSN,

which it will send to PFS, along with the torque results

FIGURE 9: Process Flow for a NON-ALS Station using R* mode

R* MODE (NON-ALS)

PERFORM/REPEAT

RUNDOWN

IS IT A PASS

OR FAIL?

SEND

RESULTS TO

PFCS

pass

HAVE ALL

OPERATIONS BEEN

COMPLETED

SUCCESSFULLY?

no

yes

fail

VEHICLE ENTERS

STATION

PFCS SEND RESULTS

AND NEXT OPERATION-

REQUIRED TSN TO PFS

SEND 'FAIL' TO

PFS

NON-QAS – R* MODE (NON-ALS)

21

B* - This is a mode of sequencing that requires barcode reading and it is used for process

equipment. A barcode reader is used by the operators to scan the barcodes on the

part/vehicle. For this mode, the station can only be set up as a Multi Spindle/Single Bolt

station. The sequence of operation for B* mode is as follows:

1. Vehicle enters station and barcode is scanned and sent to the process equipment.

2. The operator performs the operation and the Process Equipment sends the result

(which has barcode data embedded in it) to PFCS

If the operation is a ‘fail’,

i. PFCS sends the message to PFS and the operator gets a


If the operation is a ‘pass’,

i. PFCS sends the result and the next TSN to PFS

Note: This mode assumes that the operator is going to work on each unit that passes the

station.

NON-QAS – B* MODE (NON-ALS)

22

FIGURE 10: Process Flow for a NON-ALS Station using B* Mode

B* MODE (NON-ALS)

VEHICLE ENTERSSTATION

SCAN BARCODE

SEND TO PES

PERFORM/REPEATOPERATION

PES SENDSRESULTS TO PFCS

IS IT A PASSOR FAIL?

PFCS SENDSRESULTS AND NEXT

TSN TO PFS

pass

SEND TO PFS

fail

NON-QAS – B* MODE (NON-ALS)

23

MODES OF SEQUENCING AVAILABLE IN A QAS 1ST

GENERATION ASSEMBLY PLANT

This section of the document will be attributed to the sequences of operations and the

different modes of sequencing that can be selected in an assembly plant where QAS 1st

Generation8 is active. The modes of sequencing available in QAS 1

st Generation are

usually operated in ALS MODE where ALS stands for Automatic Line Stop. However,

there are some exceptions, as in the case of A*9. In ALS MODE, the torque results are

not only sent to PFS through PFCS but also to QAS.

Disclaimer: For the purposes of this document, QAS logic and impact on the physical

build cycle is not represented on the process flows in this documentation.

For any mode of sequencing in a typical QAS 1st Generation assembly plant, the

sequences of operations in a production line are as follows:





2. The operator performs the required torque operation for the TSN on the PFS screen


the PFD controller sends rundown data automatically to PFCS.

4. PFCS sends Pass/Fail information to QAS10

for the station.


6. The PFS receives the next TSN to be operated on from PFCS.

8 It is pertinent to note that there are two kinds of QAS, QAS 1

st Generation and QAS 2

nd Generation

(QAS NT) 9 A* will be explained in greater detail later

10 Another method of indicating the end of cycle is that limit messages are sent to PFCS when the vehicle

exits the station

24

T* - Stands for tool sequencing. The TSN is advanced when PFCS determines the

overall pass record. If on torque failure, the TSN will not be advanced and the operator

gets a chance to ‘FIX’ the problem in station. In T* mode, the sequence of operation is as

follows:




PFCS


i. PFCS will send the ‘fail message’ to QAS and the result to

PFS

ii. The operator will try to fix the problem


i. PFCS will send the ‘pass message’ to QAS and the torque

result to PFS

ii. PFCS will advance to the next TSN and will send this to

PFS



is completed


i. PFCS will send the result to PFS and a ‘fail’ to QAS

ii. The operator will try to correct the failed rundown


i. PFCS will send the ‘pass message’ to QAS but not to PFS

until it has collected the required number of rundowns, that

have pass results, for that operation11

ii. On an overall PASS, PFCS will advance to the next TSN,

which is forwarded to PFS along with the rundown results



PFCS


i. PFS will send a ‘fail’ to QAS and the result to PFS




results to PFS

11

Note: This implies that more than the required number of rundowns could be collected due to failed

rundowns.

QAS 1ST

– T* MODE (ALS)

25

ii. PFCS will advance to the next TSN and will send this to

PFS

For all of the above kinds of operations, it is assumed that every unit requires

operation. However, if a unit requires no operation, then PFCS will send a bypass

message to QAS. Below, is a flow chart representation of the process of operations using

T* mode in ALS mode.

FIGURE 11: Process Flow for an ALS Station using T* Mode

T* MODE (ALS)

PERFORM/REPEAT

RUNDOWN

IS IT A PASS

OR FAIL?

SEND

RESULTS TO

PFCS

pass

HAVE ALL

OPERATIONS BEEN

COMPLETED

SUCCESSFULLY?

no

yes

PFCS SENDS RESULTS

AND NEXT TSN TO PFS

AND SENDS 'PASS' TO

QAS

VEHICLE ENTERS

STATION

PFCS SENDS

'FAIL' TO PFS

AND TO QAS

fail

QAS 1ST

– T* MODE (ALS)

26

TF – Tool sequence on overall PASS or FAIL. The TSN is advanced when PFCS

receives a pass or fail record from the tool controller. This mode is not widely used

except in a couple of plants because most tool failures could be fixed in station. This

mode is closely related to T* except in advancement of TSN even on torque failures. The

sequence of operation is as follows:




PFCS


i. PFCS will send a ‘pass message’ or ‘fail message’ to PFS

and a ‘pass message’ to QAS

ii. PFCS will send next TSN to PFS

If no operation is performed,

i. At the end of the job cycle, QAS will stop the line and the

problem will be investigated




If the torque result of an individual rundown is a ‘pass’ or ‘fail’,


the required number of rundowns that have passed or failed

for that operation

ii. PFCS sets overall Pass/Fail flag in accordance with the


iii. PFCS sends a ‘pass message’ to QAS

iv. PFCS forwards the tool results with the next TSN to PFS






PFCS


i. PFCS will send a ‘pass message’ or ‘fail message’ to PFS

and a ‘pass message’ to QAS

ii. PFCS will send next TSN to PFS

QAS 1ST

– TF MODE (ALS)

27




Below is a flow chart representation of the process of operations using TF mode.

FIGURE 12: Process Flow for an ALS Station using TF Mode

TF MODE (ALS)

PERFORM

RUNDOWN

IS IT A PASS

OR FAIL?

HAVE ALL

RUNDOWNS BEEN

COMPLETED ?

SEND RESULTS

TO PFCS

pass

no

VEHICLE ENTERS

STATION

SEND RESULTS

TO PFS

fail

ADVANCE TSN

PFCS SENDS 'PASS' TO

QAS; PFCS SENDS

RESULTS AND NEXT

TSN TO PFS

yes

QAS 1ST

– TF MODE (ALS)

28

TX - This a tool sequence mode where more than one track number is sequenced. ‘X’

represents integers from 2 to 9. The TSN is advanced automatically by ‘X-1’ when PFCS

determines an overall pass record. On a torque failure, screen will not advance and the

operator gets a chance to ‘FIX’ the problem in station. This mode differs from T* only in

number of vehicles that get advanced at a time12

. In TX mode, the sequence of operation

is as follows:




PFCS


i. PFCS will not advance the TSN but will send the ‘fail

message’ to QAS and the torque result to PFS




results to PFS

ii. PFCS will advance to the next TSN by ‘X-1’ number of

vehicles and this will be sent to PFS



is completed


i. PFCS will send the torque result to PFS and will send a

‘fail’ to QAS

ii. The operator will try to correct the failed rundown


i. PFCS will send the ‘pass’ to QAS but not to PFS until it

has collected the required number of rundowns, that have

pass results, for that operation


Pass/Fail flag to ‘P’ and will advance to the next TSN by

‘X-1’

iii. PFCS will send all the rundowns to PFS in a single packet

of data along with the TSN



PFCS

12

Note: If X = 1, TX mode will be the same as T* mode.

QAS 1ST

– TX MODE (ALS)

29


i. PFCS will not advance the TSN but will send the ‘fail

message’ to QAS and will send the torque result to PFS

ii. The operator gets a chance to fix the problem



results to PFS

ii. PFCS will advance to the next TSN by ‘X-1’ number of

vehicles and this will be sent to PFS

In this mode, PFCS or the Tool Controller could determine the overall PASS or FAIL.

On the next page, a flow diagram showing the sequence of operations for a TX mode is

depicted.

QAS 1ST

– TX MODE (ALS)

30

TX MODE (ALS)

PERFORM/REPEAT

RUNDOWN

IS IT A PASS

OR FAIL?

SEND

RESULTS TO

PFCS

pass

HAVE ALL

OPERATIONS BEEN

COMPLETED

SUCCESSFULLY?

no

PFCS SENDS RESULTS

AND TSN TO PFS AND

SENDS 'PASS' TO QAS

VEHICLE ENTERS

STATION

PFCS SENDS

'FAIL' TO PFS

AND TO QAS

fail

PFCS ADVANCES

TO TSN BY 'X-1'

UNITS

yes

FIGURE 13: Process Flow for an ALS Station using TX Mode

QAS 1ST

– TX MODE (ALS)

31

A* - Auto Sequence mode that displays the next TSN when the vehicle exits the station.

PFCS knows when the vehicle exits the station from the Limit Messages it gets from

QAS. These messages are initiated by the limit switches in each station (refer to Figure

2). It is important to note that this is a NON-ALS MODE even though QAS 1st generation

is being used. This is because A* requires QAS for the purpose of limit messages as

mentioned above. In this mode, the sequence of operation is as follows:




PFCS


i. PFCS will send the failed result to PFS and the operator



i. When vehicle exits the station, Limit Message is sent to

PFCS

ii. PFCS will advance to the next TSN, which will be sent to

PFS along with the torque results





i. PFCS will send the result to PFS and the operator gets a



i. The operator continues performing the rundowns

ii. When vehicle exits the station, Limit Message is sent to

PFCS

iii. PFCS will advance to next TSN and will send it along with

the torque results to PFS



to PFCS


i. PFCS will send the failed result to PFS and the operator




PFCS

QAS 1ST

– A* MODE (NON-ALS)

32

ii. PFCS will advance to the next TSN, which will be send to

PFS along with the torque results

Below, is a flow chart representation of the process of operations using A* mode.

FIGURE 14: Process Flow for a NON-ALS Station using A* Mode

A* MODE (NON-ALS)

PERFORM/REPEAT

RUNDOWN

IS IT A PASS

OR FAIL?

HAVE ALL

RUNDOWNS BEEN

COMPLETED?

no

PFCS SENDS

RESULTS TO PFS

PFS RECEIVES TORQUE

RESULTS AND NEXT TSN

FROM PFCS

pass

yes

SEND 'FAIL' TO

PFS

HAS VEHICLE

EXITED STATION?

yes

SEND RESULTS

TO PFCS

no

VEHICLE ENTERS

STATION

fail

QAS SENDS

LIMIT MESSAGE

QAS 1ST

– A* MODE (NON-ALS)

33

A* - Auto Sequence mode that displays the next TSN when the vehicle exits the station.

PFCS knows when the vehicle exits the station from the Limit Messages it gets from

QAS. These messages are initiated by the limit switches in each station (refer to Figure

2). In this mode the sequence of operation is as follows:



2. The operator performs the rundown and the Tool Controller sends the

result to PFCS


i. PFCS will send a ‘fail’ to QAS and the torque result to PFS




PFCS and the overall ‘pass’ result is sent to QAS

ii. PFCS will advance to the next TSN, and will send the TSN

along with the torque results to PFS


2. Operator performs the rundowns which are sent to PFCS as each rundown is

completed


i. PFCS will send the message to PFS and QAS

ii. PFS will send the ‘failed message’ to the PFS screen

iii. The operator will try to correct the failed rundown


i. Operator will perform all the rundowns

ii. When vehicle exits the station, Limit Message is sent to

PFCS and ‘pass’ is sent to QAS

iii. PFS will advance screen to next TSN, when it receives

Limit Message from PFCS


2. Operator performs the rundown

If torque result is a ‘fail’,

i. PFCS will send a ‘fail’ to QAS and the torque result to PFS




PFCS and the overall ‘pass’ result is sent to QAS

ii. PFCS will advance to the next TSN, and will send the TSN

along with the torque results to PFS

QAS 1ST

– A* MODE (ALS)

34

Below, is a flow chart representation of the process of operations using A* mode.

FIGURE 15: Process Flow for an ALS Station using A* Mode

A* MODE (ALS)

PERFORM/REPEATRUNDOWN

IS IT A PASS

OR FAIL?

HAVE ALL

RUNDOWNS BEEN

COMPLETEDSUCCESSFULLY?

no

PFCS SENDS RESULTS

AND NEXT TSN TO PFS;PFCS SENDS 'PASS' TO

QAS

pass

yes

SEND 'FAIL'

TO PFS

HAS VEHICLE

EXITED STATION?

SEND RESULTS

TO PFCS

no


QAS SENDS

LIMIT MESSAGE

PFCS RECEIVES LIMITMESSAGE AND

ADVANCES TO NEXT

TSN

fail

yes

QAS 1ST

– A* MODE (ALS)

35

W* - This is a manual sequence mode that displays next TSN when an operator hits a

keyboard function key. On a torque failure, the operator gets a chance to ‘FIX’ the torque

problem. This mode requires the use of MPFB frequencies13

. To manually sequence the

TSN, an operator could:

a. Hit the Enter Key if MPFB frequency is set at 001 or 998


In W* mode, the sequence of operation is as follows:




to PFCS


i. PFCS will send the ‘fail message’ and result to QAS and

PFS respectively



i. PFCS sends a ‘pass’ to QAS and the torque result to PFS

ii. The operator hits a predefined function key in order to

sequence




is completed


i. PFCS will send the ‘fail message’ and result to QAS and

PFS respectively


If torque result of a rundown is a ‘pass’,

i. PFCS sends a ‘pass’ to QAS and the torque result to PFS

when it has collected the required number of rundowns

ii. All subsequent rundowns are dropped until sequenced

iii. PFCS sends the next TSN to PFS when operator hits a

predefined function key



PFCS, which in turn sends it to PFS and QAS


i. PFCS sends a ‘fail message’ to QAS and the result to PFS

13

Please refer to Page 2 of this document for the different types of frequencies and their significance

QAS 1ST

– W* MODE (ALS)

36



i. PFCS sends a ‘pass’ QAS and the result to PFS

ii. The operator hits a predefined function key in order to

sequence



FIGURE 16: Process Flow for an ALS Station using W* Mode

PERFORM/REPEATRUNDOWN

IS IT A PASSOR FAIL?

SEND RESULT

TO PFCS

HAS OPERATOR MANUALLY

SEQUENCED?

PFS SENDSNEXT TSN TO

PFS

W* MODE (ALS)

PFCS SENDS'FAIL' TO PFSAND TO QAS

SEND RESULT TOPFS AND 'PASS' TO

QAS


PFS FUNCTIONKEY

HAVE ALLRUNDOWNS BEEN

COMPLETED

SUCCESSFULLY?

pass

yes

fail

no

QAS 1ST

– W* MODE (ALS)

37

B* - This is a mode of sequencing that requires barcode reading and it is used for process

equipment. A barcode reader is used by the operators to scan the barcodes on the

part/vehicle. In ALS mode, QAS stops the production line on failures. For this mode, the

station can only be set up as a Multi Spindle/Single Bolt station. The sequences of

operations for B* mode are as follows:

1. Vehicle enters station and barcode is scanned and sent to the process equipment

2. Operator performs the rundown and the Tool Controller sends the result to PFCS

If the operation is a ‘fail’,

i. PFCS sends the result to PFS and the ‘fail’ to QAS

ii. The operator will try to correct the problem

If the operation is a ‘pass’,

i. PFCS sends result and ‘pass’ to PFS and QAS respectively;

PFCS sends next TSN to PFS

The flow chart for B* mode is shown on the next page.

QAS 1ST

– B* MODE (ALS)

38

FIGURE 17: Process Flow for an ALS Station using B* Mode


SCAN BARCODE

SEND TO PES

PERFORM/REPEAT

OPERATION

SEND TO PFCS

IS IT A PASS

OR FAIL?

DISPLAY NEXTTSN

PFCS SENDS

'FAIL' TO PFS AND

TO QAS

B* MODE (ALS)

SEND TO QAS

pass

fail

PFCS SEND

RESULTS TO PFS

QAS 1ST

– B* MODE (ALS)

39

MODES OF SEQUENCING AVAILABLE IN A QAS 2ND

GENERATION ASSEMBLY PLANT

The previous section elucidated the different modes of sequencing available in ALS

mode under QAS 1st Generation. As also noted earlier another version of QAS is

currently in use – QAS NT, also known as QAS 2nd

Generation. In this version of QAS,

some sequencing modes are also available in both ALS and NON-ALS modes. These

torque monitoring process modes are PM and W*. Their sequence of operation under this

generation of QAS will be explained in this section.

Below are important facts to note about 2nd

Generation QAS:

• QUQT screen in addition to QUNX screen are used for PFD setups

• It uses Point Arrival Messages in sequencing TSN

Disclaimer: For the purposes of this document, QAS logic and impact on the physical

build cycle is not represented on the process flows in this documentation.

Assumption: Operator will always work in station.

The sequences of operations in either ALS or NON ALS mode selected in QAS NT are

as follows:


1. QAS sends point arrival message to PFCS as a vehicle enters the station.




3. The operator performs the required torque operation for the TSN on the PFS screen


the PFD controller sends rundown data automatically to PFCS and to QAS.


6. The PFS receives the next TSN to be operated on from PFCS.

40

PM (NON-ALS) - This is a mode of sequencing where the TSN is advanced based on

- QAS Point Arrival Message (Message sent when vehicle enters

station)

- Input from tool i.e. Rundown Results

Below is the sequence of operation for this mode:

1. QAS sends Point Arrival Message to PFS through PFCS, as vehicle enters the station

If the station is setup for a Single Spindle/Spindle Bolt operation,


to PFCS


i. PFCS will send the ‘fail message’ to PFS and the operator



i. PFS will advance to the next TSN on receipt of next point

arrival message






to fix the problem

If the torque result of a rundown is a ‘pass’

i. When the number of correct rundowns have been received,

PFCS will send the overall result to PFS

ii. PFS will advance to the next TSN on receipt of next point

arrival message



to PFCS



will try and fix the problem


i. PFS will advance to the next TSN on receipt of next point

arrival message

QAS 2ND

- PM (NON-ALS)

41

PM in NON-ALS Mode does not receive keyboard functions from PFS other than ‘F2’ –

line start. The following figure depicts the flowchart for this mode.

FIGURE 18: Process Flow for a NON-ALS (NT) Station using PM Mode

PFCS SENDS

RESULTS PFS

PERFORM/REPEAT

RUNDOWN

IS IT A PASS

OR FAIL?

SEND RESULTS

TO PFCS

pass

HAVE ALL

RUNDOWNS BEEN

COMPLETED?

no

QAS SENDS POINT

ARRIVAL MESSAGE TO PFS

THROUGH PFCS, AS VEHICLE

ENTERS STATION

PM MODE (NON-ALS)

SEND 'FAIL' TO

PFS

yes

START PROCESS

fail

QAS 2ND

- PM (NON-ALS)

42

PM (ALS) - This is a mode of sequencing where the TSN is advanced based on

- QAS Point Arrival Message

- Input from operator






PFCS


i. PFCS will send the ‘fail message’ to QAS, and the latter

will send an annunciation message to PFS



i. PFCS will send the ‘pass message’ to QAS

ii. PFS will to the next TSN on receipt of next Point Arrival

Message






to fix the problem

ii. PFCS will send the ‘fail message’ to QAS, which sends an

annunciation message to PFS

If the torque result is a ‘pass’

i. When number of correct rundowns have been received,

PFCS will send the overall result and ‘pass’ to PFS and

QAS respectively

ii. PFS will advance to the next TSN on receipt of next Point

Arrival Message


2. Operator performs the rundown and the TM sends the result to PFCS, which in

turn sends it to PFS


i. PFCS will send the ‘fail message’ to QAS, and the latter

will send an annunciation message to PFS




QAS 2ND

- PM (ALS)

43

ii. PFS will advance screen to the next TSN on receipt of next

Point Arrival Message

PM in ALS Mode does not allow operator keystroke from PFS terminal except for a ‘line

start’ keystroke. Also, as an addendum to the above listed sequence of operations, this

mode also utilizes the status of a job at a particular point in time of the job-space to

transmit data.

For the purpose of this explanation, tx% will be used, where t stands for time and x

represents a percentage of the physical job space (Figure 2). For example, t45% represents

time at 45% percent of the job space. The sequence is as follows:

1. QAS sends Point Arrival Message as vehicle enters the station

2. Operator does the job - Single or Multi Spindle

If (tx < t70%) and (operator has completed job),

i. PFCS sends results to PFS

ii. PFCS sends station pass to QAS

If (tx = t70%) and (operator has not completed job),

i. QAS sends an annunciation (in the form of an alarm) to PFS



ii. PFCS sends station ‘pass’ to QAS

If (tx < t100%) and (operation failed),

i. PFCS sends ‘fail’ to PFS and QAS

ii. QAS sends annunciation to PFS as an alarm

If (tx ≥ t100%) and (operator has not completed job),

i. QAS sends an annunciation to PFS

ii. QAS sends a ‘Line Stop’ message to conveyor

QAS 2ND

- PM (ALS)

44

FIGURE 19: Process Flow for an ALS (NT) Station using PM Mode

PFCS SENDS RESULTS

TO PFS; PFCS SENDS

OVERALL 'PASS' TO QAS

PERFORM/REPEAT

RUNDOWN

IS IT A PASS

OR FAIL?

SEND

RESULTS TO

PFCS

pass

HAVE ALL

RUNDOWNS BEEN

COMPLETED

SUCCESSFULLY?

no

QAS SENDS POINT



ENTERS STATION

PM MODE (ALS)

PFCS SENDS

'FAIL' TO PFS

AND TO QAS

yes

START PROCESS

fail

QAS 2ND

- PM (ALS)

45

W*(NON-ALS) – This mode depends on the following for TSN sequencing:



Below is the sequence of operation for this mode is as follows:

1. As vehicle enters station, QAS sends Point Arrival Message to PFS through PFCS



PFCS





i. PFS will advance screen to the next TSN on receipt of next



2. The operator performs the rundowns, which are sent to PFCS as each rundown

is completed



to fix the problem


i. When correct number of rundowns have been received,

PFCS will send the overall result to PFS

ii. PFS will advance to next TSN on receipt of next Point

Arrival Message

If the station is setup for Multi Spindle/Multi Bolt operation,


PFCS





i. PFS will advance screen to the next TSN on receipt of next


QAS 2ND

– W* (NON-ALS)

46

In NON-ALS mode, keystrokes are not allowed for W*.


FIGURE 20: Process Flow for a NON-ALS (NT) Station using W* Mode

PFCS SENDS

RESULTS TO

PFS

PERFORM/REPEAT

RUNDOWN

IS IT A PASS

OR FAIL?

SEND TO PFCS

pass

HAVE ALL

RUNDOWNS BEEN

COMPLETED?

no

QAS SENDS POINT

ARRIVAL MESSAGE

THROUGH PFCS TO PFS, AS

VEHICLE ENTERS STATION

W* MODE (NON-ALS)

PFCS SENDS

'FAIL' TO PFS

PFS DISPLAYS

TSN

yes

START PROCESS

fail

QAS 2ND

– W* (NON-ALS)

47

The above-described sequence of operation applies specifically to a single tool station.

For multiple tool stations, there are some differences: In addition to sending a Point

Arrival Message to PFS through PFCS, the latter also sends ‘Required’ or ‘Not Required’

to PFS to display on the screen14

.

W* (ALS) - This is a mode of sequencing where the TSN is advanced based on


- Input from operator






PFCS


i. PFCS will send the message to QAS, which will send an


ii. PFS will send the ‘failed message’ to the PFS screen and

the operator gets a chance to fix the problem


i. PFCS will send a ‘pass message’ to QAS

ii. PFS will advance screen to the next TSN on receipt of next







to fix the problem

ii. PFCS will send the ‘fail message’ to QAS, which sends an


If the torque result is a ‘pass’

i. When number of correct rundowns have been received,

PFCS will send the overall result and ‘pass’ to PFS and

QAS respectively

ii. PFS will advance to the next TSN on receipt of next Point

Arrival Message

14

There are still some unresolved issues regarding this process in multi tool stations.

QAS 2ND

– W* (ALS)

48



to PFCS


i. PFCS will send the result to QAS, which will send an


ii. PFS will send the ‘fail message’ to the PFS screen and the

operator gets a chance to fix the problem



ii. PFS will advance to the next TSN on receipt of next


W* in ALS Mode does not allow operator keystroke from PFS terminal except for a ‘line

start’ keystroke. Also, as an addendum to the above listed sequence of operations, this

mode also utilizes the status of a job at a particular point in time of the job-space to

transmit data.

For the purpose of this explanation, tx% will be used, where t stands for time and x

represents a percentage of the physical job space (Figure 2). For example, t45% represents

time at 45% percent of the job space. The sequence is as follows:

1. QAS sends Point Arrival Message as vehicle enters the station

2. Operator does the job - Single or Multi Spindle



ii. PFCS sends station pass to QAS

If (tx = t70%) and (operator has not completed job),

i. QAS sends an annunciation (in the form of an alarm) to PFS



ii. PFCS sends station ‘pass’ to QAS

If (tx < t100%) and (operation failed),

i. PFCS sends ‘fail’ to PFS and QAS

ii. QAS sends annunciation to PFS as an alarm

If (tx ≥ t100%) and (operator has not completed job),

i. QAS sends an annunciation to PFS

ii. QAS sends a ‘Line Stop’ message to conveyor

QAS 2ND

– W* (ALS)

49

The flow chart for W* mode is shown in Figure 21.

FIGURE 21: Process Flow for an ALS (NT) Station using W* Mode

PFCS SENDS

RESULTS TO PFS

AND 'PASS' TO QAS

PERFORM/REPEAT

RUNDOWN

IS IT A PASS

OR FAIL?

SEND

RESULTS TOPFCS

pass

HAVE ALL

RUNDOWNS BEEN

COMPLETED

SUCCESSFULLY?

no

QAS SENDS POINT



ENTERS STATION

W* MODE (ALS)

PFCS SENDS

'FAIL' TO PFS

AND TO QAS

yes

PFS DISPLAYS

TSN

START PROCESS

fail

QAS 2ND

– W* (ALS)

50

APPENDIX

51

LIST OF FIGURES USED IN DOCUMENTATION

FIGURE 1 – Standard Torque Monitoring Setup Page

5 FIGURE 2 – Typical Station in a Production Line Page 5

FIGURE 3 – PFS QUNX Setup Screen for PFDs Page 6

FIGURE 4 – Process Flow for a NON-ALS Station using T* Mode Page 10

FIGURE 5 – Process Flow for a NON-ALS Station using TF Mode Page 12

FIGURE 6 – Process Flow for a NON-ALS Station using TX Mode Page 14

FIGURE 7 – Process Flow for a NON-ALS Station using W* Mode Page 16

FIGURE 8 – Process Flow for a NON-ALS Station using M* Mode Page 18

FIGURE 9 – Process Flow for a NON-ALS Station using R* Mode Page 20

FIGURE 10 – Process Flow for a NON-ALS Station using B* Mode Page 22

FIGURE 11 – Process Flow for an ALS Station using T* Mode Page 25

FIGURE 12 – Process Flow for an ALS Station using TF Mode Page 27

FIGURE 13 – Process Flow for an ALS Station using TX Mode Page 30

FIGURE 14 – Process Flow for a NON-ALS Station using A* Mode Page 32

FIGURE 15 – Process Flow for an ALS Station using A* Mode Page 34

FIGURE 16 – Process Flow for an ALS Station using W* Mode Page 36

FIGURE 17 – Process Flow for an ALS Station using B* Mode Page

38 FIGURE 18 – Process Flow for a NON-ALS (NT) Station using PM Mode Page 41

FIGURE 19 – Process Flow for an ALS (NT) Station using PM Mode Page 44

FIGURE 20 – Process Flow for a NON-ALS (NT) Station using W* Mode Page 46

FIGURE 21 – Process Flow for an ALS (NT) Station using W* Mode Page 49

Sequence Modes Document - ps.nafta.extra.fcagroup.com

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