Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. Rockwell Automation TechED 2015 @ROKTechED #ROKTechED

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Automotive supplier Quality System Modernization Drives 15 Percent Increase in OEE

Dana Mooers

Controls Engineer

Dane Mooers

This Global Tier One Automotive Manufacturer ranks among the world's leading automotive suppliers.

Products include automotive systems for vehicle control, braking, steering, suspension, and occupant safety, electronics, engine and other automotive components

One of it’s facilities in GA employs 200 employees and produces 4 million brakes per year for Ford F-250, F-350, F-450 trucks, Dodge Ram 1500, And Chrysler mini-vans and SUVs.

The Challenge

Twenty manufacturing lines each with multiple work cells containing up to eleven stations for brake assembly

◦ Brake component assembly in step process

◦ Quality measurement on established test values

◦ Pass or Fail based on essential quality metrics at each step

◦ Quality data capture at each step

Overall production performance was hampered by the need to manually manage quality metrics.

Accessing, maintaining, and upgrading the Quality System had became costly and difficult.

Quality reporting became more critical to meet customer-required real-time detail reports.

Legacy quality tracking software ◦ Proprietary code

◦ Maintenance and changes difficult and costly

◦ Lack of consolidation of data

◦ Data access difficult

Hardware ◦ Quality Control System hardware not networked

◦ Multiple standalone computers at each work cell

◦ Manual post-production metric data compilation

What was needed: ◦ Industry-standardized manufacturing intelligence

system

◦ Commercial-Off-The-Shelf (COTS) software that would not require extensive training to maintain

◦ Networked hardware across all manufacturing lines

◦ Scalable, reliable, and robust system

The Solution

Create User Defined Requirements ◦ Individual user and stakeholder requirements

◦ Key Performance Indicators (KPIs)

◦ Various data sources

◦ Interfaces such as dashboards and HMIs

◦ Gaps in the infrastructure and technology

Designed a new architecture to deliver the stated objectives and goals

Scalable, Reliable, Robust

Software and database

Data concentrator Programmable Automation Controllers (PAC)

Pass/fail functionality using PACs

Automated centralized data collection

Real time on demand reports

Verification and Training

Comprehensive data capture across all thirteen of the twenty manufacturing cells

Performance metrics for all thirteen cells on an over-time or real-time basis

Quick identification of product or quality issues

Automated report distribution to users

50%

55%

60%

65%

70%

75%

80%

85%

90%

95%

100%

2013 2014

2015 (to date)

OEE

2013-2015 YOY OEE

62% 66% 76%

2015 Goal

•Full

Assembly

System

Integrate

•Machining

•Logistics

•Quality

Prove •Roll out to

division

plants

Roll-out

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Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.

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