Transcript No Slide Title

TOYOTA
Shop Floor Application
Presented by:
Kevin O’Neil
Radio Frequency Identification
Vehicle Tracking System
Mirtec Technologies
Presented by
Kevin ONeill
AGENDA
• Mirtec Technologies
- Geographical Coverage
- Services
- Systems
- Industry
- Future
• Project Details
- Toyota SA
- Requirements
- History
- Project Phases
AGENDA
•
Application
- Phase 1 – Description
– Criteria
– Software and Interface
– EMS Products
– Duration & Value
- Phase 2 – Description
– Criteria
– Software and Interface
– EMS Products
– Duration & Value
•
Costs & Benefits
•
Competitors
•
Conclusion
•
Q&A
Company
Details
MIRTEC TECHNOLOGIES
System Engineers and Integrators
Established - 1988
Services
-
Design and Engineering
Feasibility Studies
Systems Integration
Installation
Commissioning
Consulting
Distributors
Systems
-
Batching Systems
SCADA
Field bus Systems
Control and Automation
Tracking Systems (Since January 2000)
MIRTEC TECHNOLOGIES
Industry
-
Coal Fired Power Generation.
-
Platinum,Gold and Chrome Mining and Refineries.
-
Pulp and Paper.
-
Automotive.
-
Petro-Chemical.
-
Food and Beverage.
-
Material Handling
Future
-
Radio Frequency Identification
MIRTEC TECHNOLOGIES
Location
Durban South Africa
Major Industrial City and Port Situated on the East Coast.
Offices
Map Relation
Employees
Total 18 employees consisting of System Analyst's, Engineers and Field Technicians.
MIRTEC TECHNOLOGIES
Geographical Coverage
MIRTEC TECHNOLOGIES
Geographical Coverage
Durban
Main Port
MIRTEC TECHNOLOGIES
Geographical Coverage
Durban
Main Port
Port Elizabeth
Automotive Industry
MIRTEC TECHNOLOGIES
Johannesburg
Geographical Coverage
Industrial Capital
Durban
Main Port
Port Elizabeth
Automotive Industry
MIRTEC TECHNOLOGIES
Johannesburg
Geographical Coverage
Industrial Capital
Durban
Main Port
Port Elizabeth
Automotive Industry
Cape Town
Agricultural Sector
MIRTEC TECHNOLOGIES
Johannesburg
Geographical Coverage
Industrial Capital
Africa
Future
Durban
Main Port
Port Elizabeth
Automotive Industry
Cape Town
Agricultural Sector
Project Details
THE COMPANY
SA Manufacturing
• Founded 1961
• Importer, Assembler, Manufacturer and Marketer of Motor Vehicles,and Motor
Vehicle Parts and Accessories.
• Also has the agency for Hino Trucks
• 6700 Employees
• 6 Billion Rands ($860 Million) Turnover
• Market Leader for the last 21 years – Presently 24% of South Africa Market Share
• Future plans to export to Australia – Therefore working towards WCM (World Class
Manufacturing)
• Plant Production capacity - 500 Vehicles per 8hr shift.
• Current Production – 360 Vehicles per shift (96 400 per Annum).
• Manufacture 6 Models
– Tazz, Corolla, Camry, Condor, Hi-Lux(Pick Up), Hi-Ace (Mini Bus Transporter)
PLANT LAYOUT & PROCESS FLOW
Distribution Yards
A Yard
B Yard
Body Shop
Paint Shop
Assembly Hall
TOYOTA SA
MANUFACTURING (TSM)
Vehicle Final Line
Train
TOYOTA SA
MARKETING (TSB)
PLANT LAYOUT & PROCESS FLOW
Distribution Yards
A Yard
B Yard
Body Shop
Paint Shop
Assembly Hall
TOYOTA SA
MANUFACTURING(TSM)
Vehicle Final Line
Train
TOYOTA SA
MARKETING(TSB)
PLANT LAYOUT & PROCESS FLOW
Distribution Yards
A Yard
B Yard
Body Shop
Paint Shop
Assembly Hall
TOYOTA SA
MANUFACTURING(TSM)
Vehicle Final Line
Train
TOYOTA SA
MARKETING(TSB)
PLANT LAYOUT & PROCESS FLOW
Distribution Yards
A Yard
B Yard
Body Shop
Paint Shop
Assembly Hall
TOYOTA SA
MANUFACTURING(TSM)
Vehicle Final Line
Train
TOYOTA SA
MARKETING(TSB)
PLANT LAYOUT & PROCESS FLOW
Distribution Yards
A Yard
B Yard
Body Shop
Paint Shop
Assembly Hall
TOYOTA SA
MANUFACTURING(TSM)
Vehicle Final Line
Train
TOYOTA SA
MARKETING(TSB)
PLANT LAYOUT & PROCESS FLOW
Distribution Yards
A Yard
B Yard
Body Shop
Paint Shop
Assembly Hall
TOYOTA SA
MANUFACTURING(TSM)
Vehicle Final Line
Train
TOYOTA SA
MARKETING(TSB)
PLANT LAYOUT & PROCESS FLOW
Distribution Yards
A Yard
B Yard
Body Shop
Paint Shop
Assembly Hall
TOYOTA SA
MANUFACTURING(TSM)
Vehicle Final Line
Train
TOYOTA SA
MARKETING(TSB)
PLANT LAYOUT & PROCESS FLOW
Distribution Yards
A Yard
B Yard
Body Shop
Paint Shop
Assembly Hall
TOYOTA SA
MANUFACTURING(TSM)
Vehicle Final Line
Train
TOYOTA SA
MARKETING(TSB)
PLANT LAYOUT & PROCESS FLOW
Distribution Yards
A Yard
B Yard
Body Shop
Paint Shop
Assembly Hall
TOYOTA SA
MANUFACTURING(TSM)
Vehicle Final Line
Train
TOYOTA SA
MARKETING(TSB)
COMPANY REQUIREMENTS
• Due to the introduction of SAP into TOYOTA , it was realized
that an Automatic Tracking System had to be implemented. The
main reason being to ensure Real Time WIP (Work In Progress)
information for use on the shop floor, stock control and Financial
Management
• To achieved this the ultimate objective would be to have the
Auto Tracking operational from the start of the production
process (Body Shop) through to Vehicle Distribution throughout
the country.
HISTORY
• Job cards Processed Manually.
• Vehicles moved no faster than the paper work flow.
• Fitment and distribution planning was done only on what had
physically reached a workstation. With a result - no forward
planning.
• Stock holding in the Distribution Yards was 3 days due to
manual paper work processing.
• NO REAL TIME DATA!!!!!
PROJECT PHASES
Toyota’s decision was to introduce an Auto Radio Frequency ID
Tracking System within the plant and implement this in two
phases.
• Phase 1 – Paint Shop (Dollies and Hangers)
– Dual purpose installation
- Tracking of Vehicles
- Tracking of Vehicle Carriers for maintenance purposes
• Phase 2 – Complete Process
Fixed RF Tag on the vehicle throughout overall process
capable of withstanding harsh paint shop environment.
PHASE 1
• Tag Mounting
- HANGERS
- DOLLIES
PHASE 1
Hangers – Process Data
Method
Temp
- Pre-degrease
- Degrease 2
- Water Rinse 1
- Zinc Phosphate
- Demineralized Water Rinse
- E-Coated at 300 VDC Electrolytic
- Rinse
Diptank
Diptank
Spray
Diptank
Spray
30 °C
Spray cold
water
50°c – 55 °c
50°c – 55 °c
Cycles : 1.09 per day – 288 per annum
50°c – 55 °c
PHASE 1
DOLLIES – Process Data
Duration
Temp
Primer ovens 1-4
- Oven Zones 1
- Oven Zone 2
- Oven Zone 3
- Oven Zone 4
8 mins
8 mins
8 mins
8 mins
195 °c
180 °c
170 °c
165 °c
Colour ovens
- Oven Zones 1
- Oven Zone 2
15 mins
15 mins
215 °c
165 °c
Cycles : 2.13 per day – 563 per annum
PHASE 1
13.5MHz International standardized frequency
Products Used
PHASE 1
13.5MHz International standardized frequency
Products Used
• RF Tags - HMS 150 HT
- Quantity 500
PHASE 1
RF Tags - HMS 150 HT
- Passive (No Batteries)
- Read/Write
- 736 bytes memory
- Baud Rate 9600
- -40 °C to 240 °C
- Reusable
- NEMA 6P/13(IP 68)
PHASE 1
13.5MHz International standardized frequency
Products Used
• RF Tags - HMS 150 HT
- Quantity 500
• RF Readers– HMS 820
- Quantity 14
PHASE 1
RF Readers– HMS 820
- Integrated Antenna
- 4 Input/Output points
- Host Interface (Com 1)
-RS232/RS422/MUX 32
- Auxiliary RS232 serial port.
- 1000 bytes/sec transfer speed.
- NEMA 4 (IP 66)
PHASE 1
13.5MHz International standardized frequency
Products Used
• RF Tags - HMS 150 HT
- Quantity 500
• RF Readers– HMS 820
- Quantity 14
• Interface module – MM80
- Quantity 1
PHASE 1
MM80 MicroMux – Bus module
- RS232/RS485 converter
- Mux 32 protocol
- C programmable
- 9600 & 346K baud communication
- Network up to 32 devices
PHASE 1
Software and Interface
• In-house Custom Written Software
• Visual C++
PHASE 1
Software and Interface
- 2 Alternate interfaces
- RS232 to Token Ring Thin Client (VTS)
- RS485 (Mux 32) to EMS Data base
(Maintance)
READER STATION ID.
001
034
035A
035B
037
040
045A
045B
0
1
2
3
4
5
6
7
030
042
041
044A
44B
048
13
12
11
10
9
8
THIN CLIENT
EMS READER
MUX ADDRESS
RFID -CPOI
RS232
REV.
01
MM 80
DESCRIPTION
READ STATION 001 ADDED
MAINT.PC MOVED
DATE
BY
11.00
KO'N
M IRTEC TECHNOLOGIES
DRAWN
DATE
P.O.BOX 20161
TEL:(031) 5636611
APPR'D
DURBAN NORTH,4016
FAX:(031)5635433
SCALE
TITLE:
RFID READER NETWORK
RS485 MULTIDROP
PROJECT:
DWG NO:
TOYOTA - PAINT SHOP VTS
RFID/P001/TSM/201
SHT No
PHASE 1
Duration & Value
- Total Project 12 weeks
- Cost R600 000($85 000)
PHASE 2
• Description
Tracking of Vehicles.
96 400 Units per annum.
PHASE 2
• Description
Tracking of Vehicles.
96 400 Units per annum.
PHASE 2
• Criteria
- 6 different models.
- No common mounting position.
- Withstand Harsh conditions (200°c).
- Cost < R35 ($5) per Tag.
PHASE 2
13.5MHz International standardized frequency
Products Used
PHASE 2
13.5MHz International standardized frequency
Products Used
• RF Tags – LRP 250 HT-FLX
- Quantity 96 400 per annum
PHASE 2
RF Tags - LRP 250 HT-FLX
- Passive (No Batteries)
- Read/Write
- 48 bytes memory
- Reusable or Disposable
- Adhesive backing
- -40 °c to 240 °c
- NEMA 6P/13(IP 68)
PHASE 2
13.5MHz International standardized frequency
Products Used
• RF Tags – LRP 250 HT-FLX
- Quantity 96 400 per annum
• RF Readers– LRP 820-08
- Quantity 71
PHASE 2
RF Readers– LRP 820-08
- Read/Write multiple tags
simultaneously
- 4 Input/Output points
- Host Interface (Com 1)
-RS232/RS422/MUX 32
- Auxiliary RS232 serial port.
- NEMA 4 (IP 66)
PHASE 2
13.5MHz International standardized frequency
Products Used
• RF Tags – LRP 250 HT-FLX
- Quantity 96 400 per annum
• RF Readers– LRP 820-08
- Quantity 71
• Portable reader – Formula 7400
- Quantity 5
PHASE 2
Portable reader – Formula 7400
- I.Code Identification
- Read RFID and Barcodes.
- Based on a 486 processor.
- Integrated full RS232 and
IrDA Ports
PHASE 2
13.5MHz International standardized frequency
Products Used
• RF Tags – LRP 250 HT-FLX
- Quantity 96 400 per annum
• RF Readers– LRP 820-08
- Quantity 71
• Portable reader – Formula 7400
- Quantity 5
• Pass through Gate Antenna
- Quantity 1
• Interface module – MM80
- Quantity 9
PHASE 2
Software and Interface
• RS232 interface with Token Ring Thin Client within
TSM Production Plant.
• RS485 Multi drop Network throughout TSB Distribution
Yards.Interfaced to TSM via Token Ring Gateway.
• Wonderware IN-TRACK software.
• SAP Management System
PHASE 2
Duration & Value
(Excluding Software and Token Ring Network)
- Total Project 6 months
- Cost R1.6 million ($230 000)
- Tags monthly consumable.
COSTS & BENEFITS
• Phase 2
Overall Vehicle Tracking Project
- R9 500 000 ($1.357 000)
-
Manual data capture – redundant
Real Time/Work In Progress information available.
Reduction of Stockholding.
“ONE DAY STOCK REDUCTION EQUATES TO R35 ($7)
SAVING PER UNIT IN FINANCING COSTS”
96 400 Units per annum @ R35 = R3 374 000 ($482 000)
COMPETITORS
• Siemens
• Baumer Ident
• Impro (SA)
– First two competitors products very expensive
– Third competitor products failed during trials
CONCLUSION
•
It is believed that this VTS project will
move TOYOTA towards World Class
Manufacturing.
Q&A
?