Automated Line-side Solutions to Meet Honda MPRs for Labeling, Packing & Shipping

Transcription

1 for Labeling, Packing & Shipping A Vision Sensor Confirms a Part is Correct and In-spec Simplifying Processes... Standardizing Excellence.

2 Enables Compliance with Honda MPRs for: 1. Pre-production 2. Process Set-up 3. Production / WIP 4. Re-pack / Re-label 5. Small Lot 6. Pass thru 7. Shipping 8. Accountability & Traceability Automated Line-side Solutions 2

3 How SPEDE Solutions Meet MPRs: 1. Error Prevention Prevents mix-ups of RH &LH parts Prevents wrong or scrap part from being packed Prevents missing components in a kit Prevents under- or over-filling dunnage 2. Tool Validation Validates a Tool / Die is correct at Start-up or Changeover Interfaces to test jigs Prevents mis-labeling of similar parts 3. Accurate Production Data Identifies / counts good pieces vs. scrap Displays real-time piece counts, label status, run data, etc., at line-side Counts only good pieces toward pack count Qty 3

4 4. Real-time Labeling & Poka Yoke SPEDE interfaces to PLC, Vision, Scales, Host apps PLC supplies part number / run data / count Vision counts / verifies manufactured part is good Vision or Scale verifies dunnage is correctly filled Host ERP / EDI supplies label data Prints serialized label when pack count is correct Interface to Weigh Scale ensures Packed Quantity is correct 5. Production / WIP Prints serialized Internal (WIP) or Customer label Production / WIP receipts data can be sent to ERP Scan serial number on WIP label to create new Honda label 6. Re-pack / Re-label Scan serial number on container to be re-packed /re-labeled Verifies correctness of Part before re-pack / re-label 4

5 7. Small Lots Controls non-standard pack counts at End of Run / End of Shift Controls partial containers of parts available for re-pack or re-work 8. Pass-Thru & Re-pack Validation Uses Vision to read symbols on Supplier Label to confirm part is correct for re-pack 9. Shipping SPEDE label data sent real-time to your EDI/Shipping application Partial containers / Split containers do not update EDI 10. Process Control Automates and standardizes processes to ensure quality control Confirms correct process is being followed in real-time 5

6 11. Accountability All SPEDE operations require Associate to sign-in All transactions/events are retained & accessible in SQL database 12. Traceability Serial number is linked to each part s production data Traceability by part, lot, container, line, run date, associate, etc. Forward traceability from production -> shipping Backward traceability from production -> raw components -> suppliers 6

7 Using PLCs for Line-side Labeling: PLC supplies Part Number, Run data, Piece Count - Triggers a label when a pack count of Good Parts is reached - Can interface to test jigs to identify Scrap - Can use a SPEDE PLC at production lines if no production machine PLC SPEDE controls piece counts at Start of Run, End of Run SPEDE controls partial packs & counts at End of Run, End of Shift SPEDE collects PLC data for Traceability, Accountability, OEE analysis - Can display real-time production data at line-side on TouchScreen PLC SPEDE Database Real-time Production Data: Part Number Operator Nbr Shift, Date WO Nbr Lot Nbr Machine Cycles, Cycle Timestamp Part Counts : Good, Scrap, Re-work Machine Stats & Metrics, etc. 7

8 Using Weigh Scales for Line-side Labeling: SPEDE integrates to existing scale to receive weight Weight can be used for piece counting / full pallet validation Adjustable tolerances to accommodate piece weight variances Actual weights collected and stored with label data Optional integration with Vision to provide: Vision check to ensure correct part Weight verification to ensure part is placed in dunnage 8

9 Using Vision Sensors for Line-side Labeling: Vision can be used for: Part Validation: Is this a good part? (vs. scrap or re-work) Part Verification: Is this the correct part? Part Counting: up to pack count Kit Validation: Is Kit complete and correct? Dunnage layer validation: all slots filled? No slots overfilled? Can read 2D serial on individual parts for accurate counts and traceability Jack Kit with open slots 9

10 How SPEDE Vision Prevents Packing Errors Vision Sensor is trained to recognize a part number by its unique attribute At Packing, the part is moved under the sensor Sensor uses image capture & pixel analysis to identify the part If part is correct, the running part count is incremented If part is wrong, an audio/visual signal prevents a packing error When pack count is reached, SPEDE prints a container label Automated Line-side Solutions Part to be Identified Keyence Vision Sensor Vision Target Area 10

11 Using Vision for Packing / Labeling at Line-side Used when Parts are packed at the production machine Used if no PLC is present to count parts Vision sensor identifies and counts good parts Operator can press a TouchScreen to record scrap Automated Line-side Solutions SPEDE prints the container label at pack count of good parts Vision Sensor Vision-directed Line-side Labeling Production Machine Finished Parts Pack Station Shipping Container 11

12 Honda Suppliers Using Vision for Packing Control Sample of 3 SPEDE Customers... Automated Line-side Solutions Sonoco Vision is set up on a mobile cart Nissin Brake Vision is set-up on a fixed table Bumper Filler Machined Casting Jack Kit Nisco A Laser etches 2D Serial Number Vision reads the 2D Serial Number Door Trim 12

13 Interfacing to Devices and Host Systems Automated Line-side Solutions Production Area IT Area Host Computer SPEDE PLC TouchScreen PC Push-button Production, Part, PLC, Label Data b Part Nbr and EDI Data Your PLC Weigh Scale WiFi Bridge Vision Scanner Part Nbr and EDI Data Label Printer SPEDE Application Server SPEDE DB Production & Label Data User/ System Events, Good/ Scrap Counts, Data printed on Labels, PLC Data/Metrics, etc. SPEDE Data Your Shipping and ERP Apps SPEDE Server Hardware Requirements Local Windows server, MS SQL, 500GB Hard Drive, remote access Local Network Requirements TCP/IP to SPEDE Server TCP/IP to production PLC Prefer WiFi to SPEDE server, wired ethernet to PLC Simplifying Processes... Standardizing Excellence. 13

14 SPEDE Line-side Solutions Boost your Bottom Line: Every Container has the Correct Part, Correct Count, Correct Label Every Label has the Correct Data Real-time Part Traceability and Auditability Production Data sent automatically to Host Systems Real-time OEE information to improve production efficiencies Production reports, inquiries, dashboards Meets Honda MPRs for an Accurate Labeling Process Everybody s Happy... QC, Management and Your Customers! Simplifying Processes... Standardizing Excellence. 14

15 To Discuss your Line-side Project... Please Contact: Learn More. Bob Bunsey ext.11 About Us: SPEDE Technologies is a software and systems company with 30+ years experience in the automotive industry. Our specialty is Automated Line-side Solutions that streamline and error-proof processes for Labeling, Packing, Shipping and Traceability. Our Customers are mid-size to Fortune 500 auto suppliers with multiple plant sites throughout the U.S. and in Mexico. They rely on SPEDE Automated Line-side Solutions to keep their mission-critical processes running smoothly, 24/ , SPEDE Technologies Detroit Road Cleveland, OH Simplifying Processes... Standardizing Excellence. 15