Precision painting with Dürr at Volkswagen
Car manufacturers can invest up to Euro 100 million for a new paint shop. An investment not to be sneezed at which means the system must work hard for many years to be worthwhile. Dürr is the world’s leading supplier of paint shop systems for automotive manufacturers and at their headquarters in Stuttgart, Germany only one word is needed to describe the culture,
Quality.
ATS is a preferred supplier at Dürr and supports the Control System group with extra capacity and knowledge. During a recent visit Mike James, Group Managing Director of ATS, wanted to know Dürr’s vision of the future and how the control philosophy would develop.
Helmut Kohler, Manager Control Systems, enthusiastically explained how his group builds quality into the automotive paint systems. Starting with PLC based Control Systems, Dürr has also developed a monitoring and operating system called EMOS (Epuipment Monitoring Operating System).
EMOS is the operator’s interface to the system whereby all relevant information about system conditions is available to the operator. By using uniform operator panels and applying a uniform operator philosophy throughout the whole system different types of user groups (managers, operators and maintenance personnel) are able to quickly and efficiently call up information.
To provide ‘brains’ to the system, Dürr is using the so-called EcoDBS(Dürr Basis Software). EcoDBS is composed of ready-to-use software building blocks for PLC control systems. These building blocks have a standard interface (input and output definitions) through which the functionality can be manipulated. Each hardware device has it’s own building block. Using these blocks makes it easier to ‘build’ the complete system. It’s just a matter of connecting the interfaces.
The I/O modules Dürr is using are called EcoDIM21 (decentralised intelligent modules for the 21st century). These modules are decentralised I/O modules, connected to each other using the latest Fieldbus technologies.
The Volkswagen Project
In the spring of 2002, Dürr implemented, for the first time, a component-based automation paint shop system at Volkswagen AG in Wolfsburg. A EcoDIM21 module controls each section in the paint shop. Each of these modules includes an ET 200S distributed I/O station with an IM151 CPU. All EcoDIM21 modules are networked via Profibus using the new, open PROFInet communications standard.
The resulting PROFInet components of all EcoDIM21 modules are first imported into a Simatic iMap engineering tool. With this tool the communications between the components can be configured in a simple graphical approach. A Simatic Net PROFInet OPC Server on the server PC is used to communicate with the EcoDIM21 modules using a Simatic Net IE/PB Link as Profibus to Ethernet Gateway. (The IM151 CPU’s are programmed using the new EcoDBS for OPC).
The 2 server PC’s (OPC-Master as server and EMOS 1 as hot-standby server) are equipped with Microsoft Windows 2000 and Wonderware InTouch and serve as the foundation for EMOS. The above-mentioned Simatic Net PROFInet OPC Server communicates to the EcoDIM21 modules controlling the process technology and a Wonderware I/O server for Siemens SIMATIC NET S7 communicates with the S7-400 PLC’s that control the conveyors.
The OPC-Master PC is connected to Siemens Sicalis production monitoring and control system. This is the layer that resides on top of the Dürr EMOS layer. Sicalis PMC is responsible for the logistics operations within the paint shop. Sicalis stores production data and process parameters in a database. The data in this database is made available to the EMOS application using an ODBC link.
User Interface Development
Besides testing and installing the OPC link between the Siemens hardware and the server computers, ATS engineers were also responsible for the user interface development. They designed all the necessary ‘screens’ according to the EMOS standard and philosophy. The screens had to comply with numerous standards that are valid for the automotive industry. The communication points through which the EMOS application is communicating with the OPC server were created and connected using Dürr’s new design tool, the Tag Generator OPC. For the standard S7-PLC-controlling the conveyor technology the DATABASE-Generator 2 was used to create the EMOS variables. This tool was also used to define the alarm reports used within EMOS.
The EMOS- Master-Application runs on the server on which it also is developed. The operator PC’s (Clients) obtains a local copy from the server. When the application is changed the developer notifies the Clients and the new application is copied automatically. The Clients connect to the server computer using the SuiteLink Protocol. The SuiteLink Protocol is based on TCP/IP. It is best used for industrial applications where Value Time Quality, extensive diagnostics, and high throughput are important. The first dry-run was 3 months after the start of the project and 3 months later, the paint shop was taken into production.
This was an interesting project in many ways. It was the first time Dürr implemented component based automation. It was also the first time that Dürr used OPC. But the most attracting point is that this project was realized with state of the art hard- and software.
ATS Project Leaders Jens Bangert and Frank Dilcher were involved in this large project. Jens was responsible for the process technology and Frank for the conveyor technology. Main points of the project:
1. New OPC Standard
Using S7 OPC for the first time, a new basis standard for OPC had to be created for programming the PLC. To achieve this, four new building blocks were used in the PLC. EMOS followed the new building blocks and created new symbols for the process technology (pumps, valves, drives, etc) based on the standard. Each status window for the new building blocks had to be created and tested.
The variables for EMOS were generated with the new Tag Generator OPC. This tool was optimised during the whole project.
2. Screen Development
Using the transport technology and mechanical specifications for the process technology the screens were designed and developed following the DÜRR- EMOS standard.
The communication points (tags) listing were created and connected using Dürr’s design tools, the Tag Generator OPC and the DATABASE -Generator 2. These tools are also used to define the alarm reports.
3. Preparations and Commissioning
Installation of the EMOS Computer with software:
• Win2000
• InTouch 7.1
• Wonderware I/O Server for Siemens SIMATIC NET S7
• Simatic Net Version 6.0
• Installation of the EMOS-Computer in the operator station
• Connection of the EMOS-Computer with the TCP/IP network
• Configuration of the network with the VW system managers
4. Commissioning
• Test of all applications with the PLC programmers, the transport engineers and the operators.
• Optimisation of the EMOS application
• Integration of the project extensions
• Optimisation and testing of the OPC server software in close teamwork with Siemens engineers
5. Training
• Instruction and training of the operators on the EMOS application.
Conclusion
In a project of this size with the adoption of new standards it is not surprising that much time had to be devoted to correcting some standards and the interfaces. This practical approach significantly improved the standard “library” without causing any serious delays.
When asked about the next steps in Dürr’s strategy Helmut Kohler explained that the key word is harmonisation. Dürr has acquired several companies in the last few years and each has followed a different controls strategy. By harmonising the controls strategy throughout the group Helmut expects to achieve efficiency and quality improvements. He also feels that more work will need to be done to integrate control and operator interface systems into the whole business process. A more advanced version of EMOS called EMOS-SM (System Management), standing for Supply Management, goes a step further than EMOS bringing the control process into contact with ERP (Enterprise Resource Planning) systems. Helmut feels that Dürr will devote much time to this product area and offer customers new modules as software technology continues to advance.
The continued drive towards lean and mean manufacturing technologies is vividly apparent in Dürr’s thinking and choice of partners like ATS. Helmut stated that ATS’ expert software knowledge had helped to bring many projects to a successful conclusion. ATS continues to offer a customer independent advice, rather than supplier driven solutions.
Connectivity in Dürr
-
Our customer, a leading company in the automotive sector, has achieved major benefits by implementing Six Sigma. The customer was able to reduce the amount of rubber used in the injection machines purge process.
[...]
-
Thanks to a Six Sigma project and new defect-tracking software system that helps collect quality data in real-time, Navistar’s Chatham, Ontario, plant has forged a path to in-process quality improvement.
“Navistar has made a substantial commitment to improving quality and customer service,“ says Rick Burns, the master black belt in charge of the Chatham implementation. “The Six Sigma initiative has refocused our efforts on making sure that we produce the best heavy trucks in the Word.“
[...]
-
Toyota Car Manufacturing utilizes the famous Toyota Production System and the Toyota Way philosophy. Toyota is recognized as the world leader in applying Lean Manufacturing techniques and regularly tops the list of independently ranked quality ratings for their passenger cars. As part of Toyota’s Kaizen or Continuous Improvement process ATS has implemented and supports a number of MES applications at Toyota. This briefing refers to two of the solutions already implemented.
[...]
-
When Paccar (the Leading Global Truck Manufacturer) contacted ATS with the problem of how to engineer the Battery Module Assembly process for their new assembly line in Mexico, they didn’t have much time; initial production was scheduled within two months. The ATS expert mechanical engineering team set to work immediately to examine the process and come up with a solution.
[...]
-
When Paccar were faced with quality issues on their truck bodies, they looked to ATS to review their ideas and turn them into reality. The problem was that the operation to apply the seals to the top of the trucks was prone to accidents and damaged body shells resulted.
[...]
-
Kistler/Chrysler FD-SPC Project
When you’re producing engines at a rate of one every 96 seconds you can’t leave process control to the end of line inspections. You need to detect when a fault occurs as soon as it happens and take immediate action or you end up with a very large amount of scrap.
Earlier this year ATS was approached by Kistler group with the question “did we have a solution that could record and monitor the vast amounts of data concerned and integrate with their advanced measurements systems?” The answer was a resounding “yes”.
[...]
-
Efficient Product Handling at GM and Faurecia
Fast Efficient Solutions to support Lean Production.
A key ingredient in achieving Lean Production operations is having good work practices to monitor and move the product (and components) around the factory.
Anyone who has ever worked in a high volume/high speed operation will vouch for this.
Organizing product flows, maintaining buffer stocks and keeping track of shop stock levels all too often proves elusive. Line stoppages, overstocking and product damage often result.
[...]
-
When you’ve designed a production line to meet a given output level and your customer demand reaches more than double that level, you’re working three shifts, seven days a week and you still can’t keep up, you need to take action. You essentially have two choices – you invest in a second line or you fix the existing one to increase throughput. The latter is what Faurecia the Automotive Interiors company chose on their Malibu assembly line.
[...]
-
When faced with the question of how to organize the part feed operations for their Glove Box Assembly line, Faurecia (the world renowned auto components manufacturer) turned to ATS for assistance.
[...]
-
When designing a system to run a production line which must fulfill orders with only 3 hours notice, the possibility of carrying inventory is non-existent and the impact of failure is enormous, you must think hard about the solution you come up with.
This was case early last year when Faurecia engaged ATS to design and deploy just such a system for their new JIT doors line for the new Cadillac CTS.
[...]
-
Airbags Blow Up Safely with Best Practices in the Automotive Industry
Visteon Berlin produces instrument panels for the latest Ford Car. The panel has an invisible door for the airbag and the door must operate properly if the airbag is activated. In this project state of the art software is implemented to track the production process, detect errors and make sure no unsafe product is shipped to the customer. By logging all critical process steps Visteon can store the data and provide Ford with production details at anytime. The software used is Activplant from EMT.
[...]
-
Presstran Industries is a division of the Cosma group, part of Magna International, one of the world’s largest tier 1 auto suppliers. Located in St. Thomas, Ontario, Presstran’s 300,000 square foot facility employs a staff of 800 in both its press and assembly departments. Presstran specializes in heavy steel stamping and robotic spot and mig welded assemblies. The facility ships over 200,000 chassis parts per day to various Magna operations, and to automakers in North America and Europe including DaimlerChrysler, Ford, General Motors and Jaguar.
[...]
-
Project Description:
Implementation of full product traceability for three production locations in the Netherlands and Germany in the Automotive Industry. The product traceability included unique identification of individual components and complete assemblies.
Also registration of important, safety related, process values was achieved as well as automatic lockout of defective items in the production line and controlled rework facilities.
[...]
-
Car manufacturers can invest up to Euro 100 million for a new paint shop. An investment not to be sneezed at which means the system must work hard for many years to be worthwhile. Dürr is the world’s leading supplier of paint shop systems for automotive manufacturers and at their headquarters in Stuttgart, Germany only one word is needed to describe the culture, Quality.
[...]
-
Robert Bosch Australia is a leading manufacturer of automotive components and an important subsidiary within the German Bosch Group. The company first contacted ATS to help with a diode manufacturing process. The process was unpredictable with erratic quality and production levels. ATS’s success in solving this problem led to a study of how to improve Bosch Australia’s Overall Equipment Effectiveness (OEE).
[...]
-
ATS has completed a wide range of applications for the automotive industry. Special projects have included INTERBUS connectivity with Allen-Bradley PLC’s whereby a major auto manufacturer and the control supplier asked ATS to write a standard software protocol for implementation with PLC backplane communications modules.
[...]
-
Written in C, this application connects a camera with a TCP/IP network. The camera monitors the exact position of components being rolled onto a tyre during fabrication and the driver communicates the results to a PLC connected to a TCP/IP network. The PLC then issues instructions to motors to constantly adjust the positioning of the tyre components during fabrication. A very high speed process.
[...]
-
Another very large application included painting booths using InTouch SCADA software with Mitsubishi and Siemens PLC’s.
[...]
-
Special projects have included INTERBUS connectivity with Allen-Bradley PLC’s whereby a major auto manufacturer and the control supplier asked ATS to write a standard software protocol for implementation with PLC backplane communications modules.
[...]
-
A car manufacturer in Australia chose ATS as their preferred supplier for industrial control training. They quoted ATS’s independent, professional and flexible approach as the reason to choose ATS Training. Custom-made training courses are being developed for engineers and maintenance staff.
[...]
-
In this ground-breaking experimental project ATS wrote PLC, MES (Manufacturing Execution System) and SCADA software for a steel manufacturer who built a new plant to produce doors for a major car manufacturer. Laser welding separate door components has replaced the old method of producing doors from a single sheet of stamped metal. This significantly reduces the weight of the doors thus helping to improve fuel efficiency. The MES and SCADA software was written in SQL and Visual Basic.
[...]
