advanced manufacturing article highlighting pinpoint information systems
TRANSCRIPT
w w w. a d v a n c e d m a n u f a c t u r i n g . c o m
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AMT Showcase n IT Project Management n Findng an automation systems integrator
20 November/December 2007 advanced manufacturing
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20 November/December 2007 advanced manufacturing
www.advancedmanufacturing.com June 2008 21
BY SCOTT BURY
Software system
points to the
path of success
for automotive
assembler In order to maintain their quality commitment
to Ford for assembling key automotive com-
ponents, Automodular needed to make sure
that all their people not only were fully quali-
fied and certified for the processes they per-
formed, but also that each person had all the informa-
tion needed to assemble each part, at the right time.
To make this happen in their plant in Oakville, Ont., Automodular turned
to PinPoint Information Systems to develop a software system to communi-
cate and verify information and track conformance to standards in real time.
Auto parts assembler Automodular is not a parts manufacturer. It buys no
materials; its business model consists of setting up state of the art facilities,
within close range of an OEM assembly plant, receiving component material
from the OEM’s tier I supply base, and assembling complex value-added
modules, and shipping in sequence to the assembly plant. In essence, Au-
tomodular sells complex assembly services to clients like Ford and General
Motors in southern Ontario, and the Midwest U.S.
Every two to five minutes each day, clients like Ford send orders to Auto-
modular electronically. The information in these orders include not only the
type of part, quantity and delivery date, but complete specifications including
exactly how the parts are to be assembled, torque tolerances and packaging
instructions. It’s up to Automodular not just to assemble the moduless, as and
when ordered, but also to ensure that all their employees operating any ma-
chines or workstations are fully certified to use that equipment to make the
part in question. And they also have to be able to prove all that for an audit.
Two and a half years ago, Automodular built a new 265,000-square-foot
plant in Oakville and recently completed a second 140,000 square-foot plant,
Jara Smrz (far left) and Corey Simon (inset) of PinPoint, along
with Automodular's Denis Thibodeau designed specialized
software for the auto assembler's Oakville plant.
Photography by Natural Selection, Juris Kornets
22 June 2008 advanced manufacturing
specifi cally to serve Ford of Canada. Today, that operation makes
instrument panels, power-train modules, front suspension and front
cradle for the Ford Edge, its twin the Lincoln MKX, and the brand-new
Ford Flex. “With those three models, and various options and builds,
there can be as many as 200 different variations of instrument panels
alone,” says plant general manager Denis Thibodeau.
The only way to guarantee that Ford gets what it wants, how it
wants it and when it wants it, is to be sure that every person involved
in production knows exactly what the order entails.
To ensure that all their equipment operators had the infor-
mation they needed at their workstations when they needed it,
Automodular turned to Burlington-based PinPoint, a company
they had used before to develop specialized software for its
Oshawa-based facility serving General Motors Oshawa Autop-
lex. PinPoint worked closely with the auto parts assembler, and
over eight months developed a unique, customized system that
they installed as the new plant was being built. When the fac-
tory went on-line, PinPoint’s system, incorporating state of the
art touch-screen technology at every workstation, was live.
The smart factory“The PinPoint system continuously receives broadcast mes-
sages from Ford, which describes what they need, when and
how they need it. That information has to get communicated to the
plant fl oor, right down to the fi ve different assembly lines,” explains
Corey Simon of PinPoint.
PinPoint’s production database sorts the information from Ford’s
order and distributes it where it’s needed. Product descriptions and
all the specifi cations each worker needs is delivered to that worker’s
touchscreen workstation.
But the system goes beyond distributing information: at heart, it’s an
"PinPoint ensures that we have completed our
value-added responsibility," says Thibodeau.
Contents page: move your mouse to
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May/June 2008
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I hope you will fully explore and enjoy this user-friendly tool to help you get the valuable information you’ve come to
expect from advanced manufacturing for more than 9 years. To help you out here are a few simple user tips:
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D I G I TA L E D I T I O Nu
24 June 2008 advanced manufacturing
error-control system. When the worker arrives at the workstation, they
have to log into the SmartScreen client application, which then checks
with the production database whether the worker has the certifi ca-
tions necessary to operate the equipment at hand, and whether they
have the necessary training on the product being assembled. If not,
the system will not allow the worker to perform the assembly.
“The SmartScreen shows every worker the latest order information
and specifi cations needed by the customer,” says PinPoint’s Jarda
Smrz. “It makes sure that the second shift has the same information
as the fi rst, and also that someone coming back after a two-week
vacation is able to work with any changes or new information that
may have come in during that absence.”
Assuming the worker is qualifi ed, the SmartScreen provides the
worker with the information needed for producing that day’s orders.
“As the module moves down the assembly line to the next worksta-
tion, bar-code scanners ensure it’s the right part in the right place.
SmartScreens display the information about the order, which parts
the worker needs, where the fastenings and joints are and so on,”
says Thibodeau. “The screen tells the worker the number of parts
needed, where the fastenings should be and the torque required on
every screw. If anything’s missed, the software won’t allow the part
of move out to the next stage on the assembly line.”
This level of verifi cation and control persists to the shipping
dock. “The PinPoint system validates that the parts have been
taken from the line in the proper order to meet Ford’s assembly
instructions,” says Thibodeau.
The SmartScreen terminal also communicates back to the produc-
tion database. This keeps management up to date, but also provides
an audit trail for the customer. Management can use a simple web
browser to see all the information about production. “The vehicle in-
formation number (VIN) can tell you everything about the car, or at
least the components manufactured by systems in our database. It can
tell you who built every part and every assembly, and whether that
person was certifi ed to do the work he or she did,” Smrz explains.
PinPoint's SmartScreen shows every worker on the
Automodular line the latest customer order information.
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AMT Showcase n IT Project Management n Findng an automation systems integrator
8 June 2008 advanced manufacturing
It was a challenging year for the Canadian auto parts industry
to say the least, but manufacturers need to keep their eyes on
the future. That was the message at this year’s
Annual Conference & Exhibition, where the
theme was “Developing 2020 Vision.”
Keynote speakers at the two-day event held
at the Hamilton Convention Centre included
Ford Motor Company of Canada President
and CEO Barry Engle and Bo Andersson,
Group VP of General Motors Corporation.
The event also featured an innovation panel
moderated by the Auto21 Network.
“What doesn’t break you makes you
stronger,” noted APMA Board of Directors
member Jan Chaplin during the association’s
Annual General Meeting, which kicked off
the 2008 Conference.During 2007, the APMA certainly did it’s
best to strengthen the industry.
“APMA’s focus and services continue to
change to meet the ever-changing environment in which
our members operate,” said APMA President Gerry Fedchun.
“Through the continued support of its members, APMA has
been very effective in garnering attention for our sector,
affecting positive change and increasing government support
while APMA itself engages in activities which enhance the
competitiveness of its members.”
Several achievements were noted, including getting the
Federal government to allow the accelerated (two-year) write-
off for new machining and equipment and
a commitment by the Ontario government
not to support a Free Trade Agreement
with Korea, unless Ontario businesses have
equal access to the Korean market.
Also announced was the launch of a
strategic initiative — the APMA Market
Intelligence Program (AMIP). It is aimed at
improving the competitiveness of Canadian
automotive suppliers by providing a low
cost, high benefit, business planning
solution. The AMIP initiative will be
powered by the industry-leading market
intelligence databases and software of
AutomotiveCompass Ltd.“Competitiveness is based on innovation.
We are helping Canadian automotive
suppliers to improve the productivity of
their planning efforts,” said Fedchun. “The
AMIP innovation combines accelerating
the planning and information access and analysis process,
improving member support services and lowering member
costs.”In other announcements, the APMA and the Canadian
Tooling and Machining Association (CTMA) will use $1.2
million in provincial funding to increase
their competitiveness and strengthen
Ontario’s manufacturing base.
“This is about strengthening the Ontario
auto supply chain from beginning to end,”
said Sandra Pupatello, Minister of Economic
Development and Trade. “We’re investing
strategically to get car companies building
in Ontario, sourcing from Ontario parts
makers, who in turn get their tooling
designed and built here too.”
The CTMA will assess shortfalls in
software skills across the industry and work
with suppliers to identify solutions. This
will include testing and evaluating software
and developing new training programs.
The APMA will pilot cost reduction
projects at a number of auto parts companies
and share the results across the industry. The association
will also engage consultants with expertise in manufacturing
cost reduction and develop new business with Japanese and
European auto makers building vehicles in North America.
“This project is going to deliver targeted, tailored advice
to help our member companies boost competitiveness and
diversify their customer base,” said Fedchun. “It’s an important
step for our industry to adjust to the new realities of our
business climate.”
Auto parts makers encouraged at annual conference
to have a clear vision of industry going forward
Delegates gather to hear one of the many guest speakers
featured at the 2008 APMA Conference & Exhibition.
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Bo Andersson of General Motors
answers audience questions.
June08.indd 8
26 June 2008 advanced manufacturing
AMTShowcase
FOCUS: MOTION CONTROL , AUTOMATION AND PLM SOFTWARE
A DVA N C E D MA N U FA C T U R I N G T E C H N O L O G Y
Drive offers scalable motion control for electrohydraulics
The HNC100-3x digital servo drive from Rexroth is a freely programmable, bus-capable NC con-
trol for electromechanical and electrohydraulic drives. It expands the range of the HNC100 family
by offering control of up to four electrohydraulic axes in one unit. According to the company, the
increased computing power of the HNC100-3x shortens scan rates. Up to eleven freely configu-
rable digital I/Os increase automation flexibility. The customer can program the sequence via a
PC using the HNC’s WIN-PED software. The NC programming provides greater flexibility of the
HNC, and it can complement existing user know-how with its common platform.
www.boschrexroth.ca
Motion control system offers
closed- and open-loop
Festo’s single-axis position controller
CMMS-ST combined with stepper mo-
tors EMMS-ST for single- and multi-axis
handling units with loads up to 20 kg,
according to the company. The Servo-
Lite mode offers a full-feature closed-
loop servo system. This differentiates the
stepper motor controller CMMS-ST from
conventional controllers. Alternatively,
the CMMS-ST can also be used as an
inexpensive open-loop system for step-
per motors without encoders. This new
stepper motor series combines
long service life and full po-
sitioning functionality with a
low price. The two-phase hy-
brid stepper motor offers high
torque, a high degree of pro-
tection and an industrial con-
nector system. www.festo.ca
Servo motors feature
higher moment of inertia
Beckhoff Automation has extended its Drive
Technology range with the introduction of the
AM3500 series servo motors. According to the
company, these new servo motors have a higher
moment of inertia, making them well suited for
machine tool axes with stringent synchronism re-
quirements. The motor flanges, connectors and
shafts of the new AM3500 series are compatible with Beckhoff’s AM3000 motors.
The new AM3500 models are available with flange sizes three to six, torques be-
tween 1.9 and 15 Nm and rated speeds of 3,000 and 6,000 rpm.
www.beckhoffautomation.comAC servo motors offer smooth
motion at slow speeds
Baldor introduced the BSM R-series, a range of ultra-
compact brushless AC servo motors offering machine
builders an alternative to stepper motors and DC ser-
vos. Capable of delivering peak torques of up to 33.63
lb-in (3.8 Nm), combined with other interesting dy-
namic performance attributes of servo motors such as
fast acceleration, the new motors are packaged in small 1.6 and 2.4 inch (40 and
60 mm) square bodies. According to the company, special construction features
employed in the motors mean that their action is virtually ‘cog free’, providing very
smooth motion at slow speeds.
www.baldor.comSoft starters for the lower price range
The Siemens SIRIUS 3RW40 soft starters in the lower power range from 10-75HP @
600V expand the performance spectrum of the 3RW40 soft starters.
According to the company, they represent a very compact and
price-attractive alternative to start-delta starters. The soft-start-
ers will reduce the inrush current and mechanical stress that
usually occurs during standard direct on line starting of AC
motors. Features include overload relay, voltage control and
current limiting technology, integrated remote reset (with-
out additional module), programmable ON/RUN output and
fault output, and polarity balance.
www.ontor.com
AM_June08.indd 26
5/28/08
www.advancedmanufacturing.com June 2008 25
The system also provides critical feedback to the individual worker
and to the manager. At the workstation, the touch-screen shows pro-
ductivity data and real-time error rates; management gets an overall
picture of the production flowing through the plant, and over the
lunchroom door, a big-screen LCD communicates overall reports in-
cluding general productivity, new instructions and the overall produc-
tivity and error rates for the plant.
“All manufacturers struggle with the same quality control issues,”
says Smrz. “They have to ensure that all the latest, most relevant work
instructions are available at the workstations where they’re needed.
They also have to be able to guarantee that the people who built the
product are qualified to do that job. And they have to be able to track
each product back to the time, the place, the workstation and the
person who produced it.”
The importance of flexibilityHaving all the necessary information immediately helps Automodular
make changeovers from product to product relatively easy. This helps
keep the company nimble, able to accommodate the rapid changes of
today’s global economy.
“As Ford moves to more flexible manufacturing systems, where
one plant can build several different vehicles, they need their suppliers
to be able to do the same,” says Smrz.
“Automodular does not buy, own or manufacture parts,” Thibodeau
explains. “We are solely an assembler of our customers’ products. Pin-
Point helps us ensure that we have completed our value-added re-
sponsibility.”
Scott Bury is a journalist and educator based in Kanata, Ont. He regularly
covers high technology and manufacturing. You can reach him at scott@
writtenword.ca.
A new joint venture between Rockwell and
Dassault Systèmes hopes to redefine how the
mechanical engineer and the control engineer
will collaborate to reduce time to market and
drive down costs — making the virtual design
and production environment a reality.
The virtual design and production environ-
ment will help enable collaborative mechani-
cal and control design with bidirectional syn-
chronization. As a result, immediate feedback
will be available on design changes, thus
enabling the testing of various “what if” sce-
narios in order to continuously optimize man-
ufacturing operations. Customers will benefit,
because manufacturing operations will be
commissioned faster with optimal production
performance.
“Manufacturers are anxiously awaiting a
solution that can turn the idea of a virtual de-
sign and production environment into reality,”
says Kevin Roach, vice president of Software,
Rockwell Automation.
The joint solution will link manufacturing
design to factory-floor control by integrating
Rockwell Software RSLogix 5000 control pro-
gramming and configuration software with
DELMIA Automation PLM software from Das-
sault Systèmes. As a result, manufacturers
can expect to reduce the cost of engineering
and ramp-up time, and continually optimize
their manufacturing operations with an accu-
rate, real-time, simulation model.
Working together with customers, both
Rockwell Automation and Dassault Systèmes
have created complementary manufactur-
ing engineering technologies, built around
strong, object-oriented data models for repre-
senting devices and operations.
“Our benchmark research finds that over
75 per cent of best-in-class manufacturers are
investing in real-time interoperability between
PLM and plant-floor technologies. In addition,
our research on digital manufacturing indicates
the best-in-class are twice as likely as laggards
to hit their deadlines by starting manufac-
turing planning prior to design release, and
simulating facility and equipment operation
during design,” says Jim Brown, vice presi-
dent & group director of Product Innovation,
Engineering and Manufacturing Research for
Aberdeen Group. “Manufacturers of complex,
asset-intensive products like automobiles are
turning to holistic factory simulation to de-
crease time to full volume production.”
The interplay between design and manu-
facturing will help increase efficiencies in the
design process and ultimately minimize the
time between design and delivery. Engineers
involved in all stages of design will have the
ability to make adjustments in real-time, in-
corporating, preserving and augmenting
knowledge rapidly across various stages of
the production life cycle.
100’s
1000’s