Case Study: Jacobs Vehicle Systems Laser Marking Creates Traceability for Truck Parts

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1 Case Study: Jacobs Vehicle Systems Laser Marking Creates Traceability for Truck Parts Jacobs Vehicle Systems moves to 100% part validation on engine brakes by installing FOBA laser marking stations with integrated vision inspection. The rocker arm for a Jacobs Vehicle Systems engine brake is marked with a traceability code applied by a FOBA laser marking system. Afterwards, the code is validated directly in the laser workstation using the built-in inspection system. The broad range of solutions FOBA marking lasers provide for automotive part traceability goes far beyond the pure laser marking of an identification code. Particularly important, what sets the FOBA solution apart from its competition, is its unique three stage closed-loop marking process HELP (Holistic Enhanced Laser Process) that covers part verification prior to marking, laser marking, and then validation of traceability codes directly after marking with just one marking laser station.

2 Case Study: Jacobs Vehicle Systems Traceability is key in commercial truck productions Jacobs' requirement for improved traceability: Code marking and 100% validation in one go In commercial truck productions where vehicles are manufactured with thousands of components produced by several suppliers from different countries around the world most components require record keeping, and traceability is key. Just before final assembly, the rocker arm is tagged with a data matrix code a 2D code including basic components and manufacturing information and a human readable content. One key requirement was that the code had to be validated on 100% of the parts and pass a C or higher grade for it to be acceptable. Additionally, the cycle time had to be held within 25 seconds. The 2D code grading process guarantees traceability of the applied mark throughout the assembly process and the lifetime of the product. Traceability, the capability of tracking goods along the supply chain, provides real-time information on where, how, and by whom parts are produced and integrated. Such an approach provides means of reducing, controlling, or eliminating recalls during production processes. An example of a traceability challenge is Jacobs Vehicle Systems Inc. in Bloomfield, Connecticut, a manufacturer of diesel and natural gas engine retarding systems and valve actuation mechanisms. To support a request from one of their largest customers for improved traceability, Jacobs was faced with the requirement to add scannable, laser-marked traceability content to the brake rocker arm during manufacturing and assembly. Jacobs Vehicle Systems Brent Mayerson, manufacturing process control engineer at Jacobs Vehicle Systems works with the FOBA Vario S20F laser marking workstation for code marking and validation. Compression release brakes, also referred to as Jake brakes, are engine brakes for large vehicles such as diesel trucks. When activated, the Jake brake opens the exhaust valves near the top of the compression stroke, releasing the highly compressed air through the exhaust system. Little energy is returned to the piston, and as the cycle repeats, the energy of the trucks forward motion is dissipated, causing the truck to slow down. More than 5 decades ago, Jacobs Vehicle Systems revolutionized the engine braking industry in the United States. Since then, the company has evolved into a global partner trusted by the world's best-known engine manufacturing brands. Process and quality requirements: On previous processes of rocker arms, products had been marked and validated in a two-step process. First, the operator 1) Laser marking (2D code and other information) 2) Validation of 2D code immediately after marking for all parts loaded the part in the laser marker and got it marked which 3) Keep cycle time within 25 seconds usually took 10 seconds; then the part was taken to a nearby located vision grading station in order to verify the 2D code grade which took another 45 seconds. This additional, timeconsuming step impacted productivity. That's why Jacobs has Marking with immediate validation not been verifying 100 % of the parts but only some 20 per day directly in the marking laser station saves and only during breaks. Moving to a fully automated solution 45 seconds production time per part and improved cycle time, guaranteeing 100% validation. This ensures 100% part inspection! option was very attractive for Jacobs. Automated validation saves 45 seconds per part After the evaluation of possible technologies to improve performance and cycle time, Jacobs opted for the laser marking capabilities of Foba because of its Intelligent Mark Positioning (IMP) vision alignment technology. Foba lasers provided some clear advantages to the manufacturing requirement of the commercial truck industry. Brent Mayerson, manufacturing process control engineer at Jacobs, comments, The fact that Foba could do 100% in-system validation eliminated the need for a separate machine. Saving space and operator time were key benefits. On the new line, the complete grading process added less than one second to the full 20-second process, a significant improvement compared to the other line s two-step operation, and a time saving of 45 seconds per part. The production throughput could be increased by 50% while achieving the goal of 100% part inspection which is crucial as recalls can have dire consequences. The ability to validate the 2D code right after the part has been marked, without the need for an operator to handle the part, eliminates extra handling that directly affects cycle time. The With FOBA's IMP technology Jacobs could reduce the labor validation process consists not only in grading the 2D code, but cost per part by 33%. This in turn represented a significantly also in validating its unique content, something that would faster, 30% to 50%, return on investment. not have been possible on a remote station without The recorded information, which include date, time, production adding a tracking process and networked devices. information, and passing code, is available for storage on a network drive or the cloud and can be used to manage customer inquiries.

3 Case Study: Jacobs Vehicle Systems The latest laser marking technology: Solves many challenges and reduces production costs With the evolution of lean manufacturing, suppliers are continuously challenged to find solutions that minimize manufacturing risks, improve yield and throughput while tracking processes in real-time. The latest marking laser developments provide significant benefits. Marking parts for traceability: Marks have to fit tight within limited product space Finding room on a product to place traceability content is often a challenge. Manufacturers and designers tend to use every available space on the part to squeeze all tracking information required. Parts traceability and record keeping of manufactured components have evolved from the human readable mechanical recording such as dot peen (micro-percussion created by a hard needle) to state of the art non-contact technology such as lasers. Lasers have opened the doors to faster and more complex marking solutions, like gray scale marking, annealing, engraving, or layer and lacquer removal. With today s technology, digital tracking of production processes has evolved and made many tasks easier. The marked content, such as the lot number, serial numbers, and a 2D code have to be readable by machines and humans. Sizing down the content is not always desirable, particularly with data matrix codes that require a minimum size as they need to be read by most commercial readers. A 2D Code with up to 31 characters will end up with a matrix of 20x20 cells. To be read from a distance of 150 mm (6") by most readers, it will require an area of 13 mm² (0.5in²). Benefits of marking lasers The use of semiconductors and fiber optics in lasers has enabled marking/engraving systems to come in smaller packages that now can sit on the user s desktop. They are rugged, air-cooled, run on standard power outlets, require close to zero maintenance, and will outlast compact fluorescent, low consumption kitchen light bulbs. Today s lasers are easier to use, and come with improved mark accuracy, stability, and performance. Combined with their lower costs of production, lasers have achieved a strong market penetration. Answering lean manufacturing requirements Motor vehicle part manufacturers are continuously pushing for further ways of reducing costs of production. Manufacturing space comes at a premium, and manufacturers are always looking at ways of packing more performance and production capabilities within a smaller footprint. Ever-smaller laser markers have to be able to produce marks on a variety of materials from metal alloys to plastics with a higher mark contrast that lasts beyond the life of the product. Traceability content has to fit in tight spaces and needs to meet their customers requirements. Traceability content typically combines a 2D symbol such as a data matrix code, human readable content, and a logo. Data matrix codes are preferred for their ability to efficiently pack information and are readable even when faced with degradation or contamination. Solving 2D code marking challenges Many manufacturers require 2D codes to meet certain standards such as the Association for Automatic Identification/Direct Part Marking (AIM/DPM) standard. The AIM/DPM standard focuses on methods to grade the quality of a data matrix code using characteristics such as the contrast and the uniformity of the mark. Challenging: precise mark alignment With limited space, the alignment of the mark can be a challenge as some of it may not fully land on the part. These slipups can look innocuous but could have a direct negative impact on the product s workmanship. Laser-integrated vision ensures high-quality marking To address these challenges, Foba s patented IMP (Intelligent Mark Positioning) vision technology basis of the HELP process (Holistic Enhanced Laser Process) offers laser-integrated validation tools: Tools that validate the part identity and automatically align the traceability content to the part. Often, parts from the same family, that can only be differentiated by a hole size or a part length, are easily confused by operators. Validating the part identity adds a layer of safety that prevents the wrong part from being laser marked. The mark alignment feature, on the other hand, compensates for those situations where the part is not properly seated in its fixture and aligns the mark to the part. HELP: Laser-integrated vision ensures process reliability before, during and after laser marking: 1: Validation prior to laser marking 2: Laser marking 3: Validation after laser marking The rocker arm (after marking) for a Jacobs Vehicle Systems engine brake rests in the FOBA laser marking workstation. Once laser marked, Jacobs Vehicle Systems' parts have complex code data that computers can track to manage the subtle differences between similar-looking parts. Laser benefits at a glance compact size saves production space mechanically rugged, air-cooled technology ensures high uptime almost no consumables and little maintenance for low running costs easy operation for efficient production high mark accuracy, high contrasts and permanent marks for high quality, counterfeit-safe marking results safe traceability flexible technology for various applications including metal, plastics and other challenging materials addressing major industry standards low production costs IMP vision at a glance IMP detects the positioning of areas/components, and adjusts the engraving/marking precisely as required. Optical part detection and automatic mark alignment Perfect for accurate automated inline processes Quality control: optical validation of marking contents (graphics, 2D codes) and their contrast and placement Added values Consistent high processing quality Faster and more efficient production Improved accuracy Increased productivity Drastically reduced product scrap

4 Case Study: Jacobs Vehicle Systems Validation of marked contents: Laser-integrated validation versus stand-alone validation Laser-integrated vision offers HELP in three stages: Laser marking with pre- and post-mark validation eliminates potential marking errors Another benefit of using marking laser systems with built-in traceability capabilities is their ability to be reprogrammed on the fly. Apart from the marking of the traceability content itself, HELP offers part verification prior to marking and extensive inspections immediately after marking in the laser without having to move the marked part to an external scanner. For Jacobs, this saved at least 45 seconds of cycle time per part in the process. Stand-alone, dedicated, industrial vision-based validation systems are not always cost effective. A stand-alone code validation station requires mechanical support structures, electrical wiring, lighting, vision programming, software communication, hardware interface, and data logging. The cost of integrating such a system can easily exceed the cost of a laser built-in tool without the flexibility and turnkey solution of a fully integrated system. Stand-alone systems are typically dedicated to a single product and work well as long as a new or a variation of the product is not introduced. In situations where changes are needed, production is faced with a fixed transition schedule, forced downtime, and strict implementation schedules. The implementation of the proper traceability process is a win-win situation for all designers, suppliers, manufacturers, and consumers. The reality is that the commercial truck industry is in constant evolution. With manufacturers managing parts coming from different suppliers around the world, in case of a recall, tracking without a traceability system would be a horrendous if not impossible job. In order to eliminate possible marking errors and defects, and to ensure code marking and proper validation for all parts, FOBA offered Jacobs extensive vision-based verification stages to both the part and the mark. The vision process HELP (Holistic Enhanced Laser Marking) and the camera system IMP, that accompany the laser marking, are directly integrated in the FOBA laser systems. Additional third party hardware or a separate inspection process for the verification and reliability of the marking process is thus not needed. Traceability marks are applied and verified with one system both efficiently and reliably. 1 1: Pre-mark verification 2 2: Laser marking (product identification) 3 3: Post-mark verification Part validation: Validates correct part and prevents marking of wrong parts. Mark verification: Validates that marks have been placed correctly (positioning, alignment, size). Pre-mark verification: Confirms that only unmarked parts are being processed. Optical Character Verification (OCV): Validates that every character marked by the laser matches the expected content. Mark alignment: Aligns the mark relative to the position of the to-be-marked part. 2D code validation and code reading: Reads the contents of 1D/2D codes (data matrix, e.g. ECC 200, GS1; QR) and compares the results to the expected content. A classification of the code into quality classes is possible. Next generation fiber laser markers. The code reading option comes with a validation tool that provides means of passing or failing codes based on factors such as the read content or the mark contrast. The positive code verification results from a data matrix code read-out that validates the mark content.

5 LASER KLASSE 4 FOBA Laser Marking + Engraving Alltec GmbH Marking laser built-in traceability pays off early Traceability plays a key role not only in managing recalls efficiently but most importantly in preventing them as it is used during the entire production process. For traceability to work, marking contents, like done by a FOBA laser for Jacobs, has to be properly accomplished. FOBA s extensive validation approach addresses and prevents most of the five major components of marking errors and defects that cause costly waste: First, users benefit from less scrap, second, users take advantage of a better product and marking quality, third, a robust accurate marking process pays off, fourth, users can rely on a cost reducing automated process and fifth, they benefit from an increase in production efficiency. Not only suppliers to the Automotive industry but also Automobile manufacturers benefit with a sophisticated, holistic process solution rather than a system solution for product identification only. FOBA s laser marking technologies are fast and cost effective. With its built-in through-the-lens (TTL) vision, the technology provides a real-time validation and tracking system that helps reduce cycle times, improve quality, and optimize the supply chain by providing information about component movements. Traceability is a key competitive advantage that resonates with higher quality standards and corporate responsibility. Benefit from: 1 less scrap 2 improved product and marking quality 3 stable and economic marking process 4 automated marking process that reduces cost 5 increased production efficiency FOBA Laser Marking + Engraving technologies are used in a wide variety of automotive marking applications including sensors, switches, fittings, dashboard electronics, lighting components, day and night design elements or motor and brake components. A variety of materials and parts are identified with text, numerical information, graphics and logos or bar codes and data matrix codes. FOBA offers a complete spectrum of system and machine solutions for laser marking and engraving as well as sophisticated vision systems for the direct, permanent and process reliable identification and validation of automotive parts and components. ALLTEC GmbH An der Trave Selmsdorf Germany T F info@fobalaser.com ALLTEC GmbH All rights reserved. Specifications subject to change without notice. CS-Auto-JVS_EN_05.16 Your local agency: LASER CLASS 4 Gem./According to DIN EN :2014