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Seufzer OPS KLU
2019-05-20
PHILIPS KlagenfurtSmart manufacturingAGV autonomous guided vehicle
Linear cutting elements
PHILIPS AUSTRIA GmbHKLAGENFURT
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Epilation heads 23 000 000 pcs50 FTE15 shifts
17 000 000 pcs30 FTE21 shifts (24/7)
May 31, 2018 Industrial Quality Management4
STANDARDIZATION - LEANMechanization2000 2016
DIGITALZATION2017 2019
SMART MANUFACTURING
2019 2020
ERP
MES
SCADA
SPS
I/O signals
Production process
Business level
Operation level
Process level
control level
Planning
Towards Future Factory 4.0 IT set up and embedding
Data
2018-10-12 MES KLAGENFURT 7
CAQ SPC
AGV+enterprise manager
improvements
Towards Future Factory 4.0 IT set up and embedding .
Towards future factory 4.0 : Automated Material HandlingRon Kruidhof
Pick-to-light
No standards in order and transport
Standardized Order & Transport Quantities
Warehousing
Material delivery to machines
Production process integrated material
delivery
Material ordering system
Material picking
Factory standardized MOQ & MTQ
Standardized replenishment quantities from/to suppliers
Factory standardized payload carriers
Factory global standardized payload carriers
Manual storage and retrieval in warehouse
Goods to men storage and retrieval systems in warehouse
Goods to men storage and retrieval systems in warehouse
Automated internal storage and transports
Automated internal storage and transports and VMI
Manually transport by operator
Manually steered transport vehicle
Fixed automated material transport infrastructure
Flexible autonomous transport with fixed path
Flexible autonomous guided transport
Automated operator to operator delivery
Automated location to location delivery
Flexible location to location delivery
Dedicated & integrated machine to machine delivery
Flexible & integrated machine to machine delivery
Reactive physical material ordering
Production planning
Kanban cards
Reactive digital material ordering
WMS
Reactive automated event triggering by hardware
Pro-active automated event triggering by machines
Pro-active automated triggering by MES /ERP
WMSWMS
WMS
Manual order picking without WMS connection
Manual order picking using printed picking list from WMS
Order picking using mobile equipment for picking list from
WMSActive, hands-free picking systems
connected to WMSAutomated order picking
equipment
WMSWMS
Pick-to-voice
WMS
WMS
2018-10-12 MES KLAGENFURT 9
• Frequent long distances from and to final assembling (400m)
• Parts transfer done by operators (10- 15 min off / shift) 3x10 000 #
• 15 min off is equal to 3 % OEE (!) per line and shift
• Continuous flow (15x2000# vs. 3x10000#)
• Quality impact on jigs due to bulk delivery by operator
• WIP reduction from days to hours !
• Reduction of boxes and jigs by factor 10 (!)
Towards Future Factory 4.0 SMART MANUFACTURING - WHY
business case
10
Smart manufacturing = LEANReduce or eliminate the 8 forms of waste that TIM WOODS represents
11
OPS KLU
BASKETS80 kg
Small aysles
OMRON 90
Coils on Palette700 kg
Aysle width>2m
MIR 500/1000
Towards Future Factory 4.0 AGV Hardware
12
• Independent power supply
• Integrated roll conveyor
• Cargo recognition
• Human interface
• Standard coupling interface
CARGO Carrier
Towards Future Factory 4.0 AGV Hardware
13
• Calling AGV – ready to ship
• Automatic ERP booking at destination
• Automatic product recognition
• Automatic loading
• Automatic scaling (optional)
Towards Future Factory 4.0 AGV Hardware
PICK DROP STATION
14
2018 AGV transport
A to B
2019 AGV integration into
process
2020 AGV integration into
ERP system
2021 AGV
Transport warehouse to
line
QtyAGV
Towards Future Factory 4.0 4 steps to success
15
SR FA
Step 1 : AGV for transport issues and pos impact on OEE
16
2018 AGV transport
A to B
2019 AGV integration into
process
2020 AGV integration into
ERP system
2021 AGV
Transport warehouse to
line
QtyAGV
Towards Future Factory 4.0 4 steps to success
2018-10-12 MES KLAGENFURT 17
18
2018 AGV transport
A to B
2019 AGV integration into
process
2020 AGV integration into
ERP system
2021 AGV
Transport warehouse to
line
QtyAGV
Towards Future Factory 4.0 4 steps to success
Call AGV
MES Terminal Display
AGV Enterprise manager
ERP
MESSCADA
SPS
I/O signalsTASK
20
2018 AGV transport
A to B
2019 AGV integration into
process
2020 AGV integration into
ERP system
2021 AGV
Transport warehouse to
line
QtyAGV
Towards Future Factory 4.0 4 steps to success
