Vehicle ManufacturingAutomation System

IntroductionPart 2 - ANDON

Tallrain / Oct 2016

1 – What’s…ANDON?

ANDON is a CALL system, when issue happened in production line, operators can pull rope, or press button to call supervisor or engineers to fix issue. ANDON system includes Call module, Notification module,

Analysis module. ANDON integrates with PMC(Process Monitoring),

AVI(Automatic Vehicle Identification), EPS(Error Proofing).

2- Call…Types

ANDON Types: Quality Call Equipment CallMaterial Call EPS Call System Call Shift Call

ANDON PLC

MES

Equipment PLC

ANDON SERVER

Equipment PLC

1 Quality Call

2Equipment Call

3Material Call

4 EPS Call

5 System Call

6Shift Call

Quality Call Occurs when Operator finds Quality Issue during operation, and needs help(from leader or engineer).

Trigger method:Operator pulls Rope or pushes Button, and then sends signal to ANDON PLC OPC ANDON Server.

ANDON PLC

MES

Rope

ANDON Server

OPCServer

Remote I/O

CP Card

IT Network

Control Network

Quality Call

Quality Call

Equipment Call

Equipment Call is triggered by Equipment Fault automatically.

Equipment PLC sends Faults or Errors to ANDON PLC OPC ANDON Server.

ANDON PLC

MES ANDON Server

OPC Server

Remote I/O

CP Card

IT Network

Control Network

Equipment PLC

COUPLER

Equipment Call

Material Call

Material Call Occurs when Operator finds a material shortage, and requires to get it delivered in time.

Trigger method: Operator pushes Call Button,

and sends signal to ANDON PLC OPC ANDON Server.

Button

Material Call

ANDON PLC

MESANDON Server

OPCServer

Remote I/O

CP Card

IT Network

Control Network

EPS Call

EPS(Error Proofing System) Call is triggered by an Error Proofing failure.

2 Inputs:1. For PLC-Control Machines such as

Filling Machine, Failure signal is sent to ANDON PLC via Coupler.

2. For PC-Control Machines such as Nut Runner, Failure signal is sent to ANDON PLC via OPC.

2 Outputs:1. ANDON PLC notifies Conveyor Stop.2. ANDON PLC syncs Calls to ANDON

Server for further analysis.

ANDON PLC

MESANDON Server

OPC Server

CP Card

IT Network

Control Network

Equipment PLC

COUPLER

Controller

Nut Runner

Equipment Server

Conveyor PLC

COUPLER

OPC Server

Failure

Command

Command

CP Card

Failure

System Call

System Call is triggered by system verification failure or system exceptions, such as AVI identification failure Call.

Example:MES reads RFID Tag via Conveyor PLC, when verification failed, then MES sends error message into Conveyor PLC via OPC, and then forwards it to ANDON PLC ANDON Server.

ANDON PLC

MESANDON Server

OPC Server

CP Card

IT Network

Control Network

Coupler

Conveyor PLC

CP Card

ERROR

Shift Call

Shfit Call is triggered by Factory Calendar automatically.

MES sends shift information into ANDON Server, and then to ANDON PLC via OPC.

ANDON PLC

MESANDON Server

OPC Server

CP Card

IT Network

Control Network

Shift Information

3- Call Level

Level Description

Normal Production line & Equipment is running normally.

Info Information, e.g. Shift Change

Alarm Alarm

Error Error & Fault

E-Stop Emergency Stop

Stop Stop

Offline Equipment is offline

Maintenance Equipment is under maintenance

Break Break

2 Categories:1) Issue, e.g.

Alarm/Error.2) Reference, e.g. Info/Break. Level definition is

shared with PMC module.

4 – ANDONNotification

ANDON PLC outputs light signal to LAMP.

ANDON PLC outputs music signal to Player & Speaker.

ANDON PLC maps data into ANDON Board via SCADA software.

ANDON PLC

MES ANDON SERVER

OPC Server

Remote I/O

CP Card

IT Network

Control Network

LampSpeaker

ANDON Board

Driver

LAMP

Level Quality Call Equipment Call Material Call EPS Call System Call Shift Call

Normal

Info

Alarm Yellow/Blink Yellow/Blink Yellow/Blink Yellow/Blink

Error Red/Blink Red/Blink Red/Blink

E-Stop Red/Blink

Stop Red/Keep

Offline

Maintenance

Break

Speaker

Level Quality Call Equipment Call Material Call EPS Call System Call Shift Call

Normal

Info Play Music

Alarm Play Music

Error Play Music Play Music Play Music

E-Stop Play Music

Stop Play Music

Offline

Maintenance

Break

Board

Level Quality Call Equipment Call Material Call EPS Call System Call

Shift Call PMC Block

Normal Green

Info Show Text Show Text

Alarm Yellow Yellow Yellow

Error Red Red Red Red

E-Stop Red Red

Stop Red Red

Offline Gray

Maintenance Gray

Break Gray

ANDON Screen

5 – ANDONAnalysis

Log data for root cause analysis.

Summary report for bottle neck analysis.

Data source of OEE report.

Thank you!

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