The company of VALEO is a part of multinational group, which is focused on design, manufacturing and sale of systems, modules and components for automotive industry. Worldwide VALEO belongs among the 10 largest suppliers in the automotive industry and it intends to promote among the first five until 2010. It focuses on the production of drowning and air-conditioning units and control panels for cars. Among the largest customers belongs SKODA, AUDI, VW, Mercedes-Benz, SAAB, Nissan, Opel, Renault, Toyota, Peugeot, Citroen Automobile.
Situation
In the company of VALEO has each of the 20 presses implemented VDO production counter. The paper disc recordes 12 hours of production and each stop. This counter is also connected to the dose of the press, which records the total number of manufactured units. At the end of the shift the press adjuster has to check VDO disc and complement codes of each stops (codes A-F). He is also obliged to manually retype total time of the production and the downtime to the PC. He also has to identify downtimes according to different types.
Business Objectives
The aim is to replace the current system by automatic system that will collect data on downtime, allowing operators to identify and adjustment, and this data will be presented at individual workplaces. For responsible staff will be available production statistics of individual presses.
Solutions
Application has two important functions. The primary function is to record information about production at the workplace. Secondary function is presentation of data to the staff (production operators, adjusters, auditors and administrators). To identify individual users (and thus for limitation of application functions according to their rights) is used Dallas chip reader. IoLogik is the only entry point for information about machines status, the information is automatically generated without need of staff active intervention. Information on "machine cycle" of IoLogik production unit means production according to define form and reference (they define type and number of the product). If the machine is in production state and cycle does not start till 1.5 times from the administrator-defined time, then it automatically switch to non-production state of machine.
Data are sent from the presses stations to the server system via Wi-Fi data networks. They are processed on the server and stored in a SQL database. There is available application on the server (CitectSCADA), which displays the status of the individual presses from the production and technical point of view (PC status monitoring on individual presses).
Benefits
The main benefit was automation of the entire process of production and the clarity of the resulting data. For operators is also important an overview of the current state of production. There can be also evaluated rate of maintenance in the event of failure on individual presses. For management there are then important production assemblies available immediately after the shift.
Technology
CitectSCADA
MSDE
Visual Studio
Server IEC Excelent
InfoPanels Unit