Vehicle Manufacturing Automation System
IntroductionPart 1 - PMC
Tallrain / Sep 2016
1 – What’s…PMC?
PMC = Process Monitoring and Control. For vehicle manufacturing, we have OEM(Original Equipment
Maker) PMC and MES PMC. OEM PMC is usually installed at Central Control Room, for remote monitoring and control. MES PMC is usually installed in Plant Floor, for production line monitoring, not engaged in control. PMC integrates with conveyors/devices via PLC.
2 - Why…PMC?
PMC is used mostly to monitor production exceptions, esp. Machine faults.
In Stamping Shop, Stamping Machines and Moulds cost over tens of million dollars. Plant capacity is limited by Machine availability.
Purchasing, installation, debugging of large machines take 1-2 years. The easiest way of extending capacity is to use machines more efficiently.
Some Welding Plants use Robots for 90% of operations. At Explosion-proof Area of Paint Shop, equipment can only be
monitored from remotely. At General Assembly Shop, PMC overview page helps managers and
engineers to find issues from complex process.
3 – PMC…Boards
PMC boards break levels down: Plant >> Shop >> Line >> Station, differ status with colors.
PMC boards can also show data pushed from MES, such as Target, Pass Rate, Shift, Welcome Message.
4 – PMC…Analysis
PMC generates Stop Time Summary Report of Stations and Machines, to help to find bottleneck of daily operations.
PMC collects data as OEE(Overall Equipment Effectiveness) input, to help to find key control points of production.
0
20
10 10
0
50
20
30
0
10
20
30
40
50
60
OP10 OP20 OP30 OP40 OP50 OP60 OP70 OP80
Daily Stop Time Report of Line X
97%
93%
97%
95%
93%
90%
95%
92%
86%
88%
90%
92%
94%
96%
98%
1月 2月 3月 4月 5月 6月 7月 8月
OEE Trend Report of Line X
5 – PMC…Architecture
OEM PLC
MES PMC SERVER
OPCServer
RemoteI/O
CP卡
IT Network
Control Network
PMC Board
Driver
OEM PLC
MES PMC SERVER
OPCServer
RemoteI/O
CP卡
IT Network
Control Network
Board
Drvier
Architecture 1: OEM PLC collects data, and then output via SCADA software such as WINCC.
Architecture 2: MES collects data from OEM PLC, and then output via reporting platform.
6 – PMC…Products
Vendor Module Platform
ROCKWELL PMC RTVIEW
SIEMENS SCADA WINCC
GE SCADA CIMPLICITY
CEC FIS KEPWARE
IGNITION SCADA KEPWARE
Thank you!
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