toyota shop floor application presented by: kevin o’neil presented by: kevin o’neil
TRANSCRIPT
TOYOTAShop Floor Application
TOYOTAShop Floor Application
Presented by:
Kevin O’Neil
Presented by:
Kevin O’Neil
Radio Frequency Identification
Mirtec Technologies
Presented by Kevin ONeill
Vehicle Tracking System
AGENDA
• Mirtec Technologies
- Geographical Coverage
- Services
- Systems
- Industry
- Future
• Project Details
- Toyota SA
- Requirements
- History
- Project Phases
• Mirtec Technologies
- Geographical Coverage
- Services
- Systems
- Industry
- Future
• Project Details
- Toyota SA
- Requirements
- History
- Project Phases
AGENDAAGENDA• Application
- Phase 1 – Description – Criteria – Software and Interface – EMS Products – Duration & Value
- Phase 2 – Description – Criteria – Software and Interface – EMS Products – Duration & Value
• Costs & Benefits
• Competitors
• Conclusion
• Q&A
• Application
- Phase 1 – Description – Criteria – Software and Interface – EMS Products – Duration & Value
- Phase 2 – Description – Criteria – Software and Interface – EMS Products – Duration & Value
• Costs & Benefits
• Competitors
• Conclusion
• Q&A
MIRTEC TECHNOLOGIES
System Engineers and IntegratorsEstablished - 1988
Services- Design and Engineering - Feasibility Studies- Systems Integration- Installation- Commissioning - Consulting - Distributors
Systems- Batching Systems- SCADA - Field bus Systems- Control and Automation- Tracking Systems (Since January 2000)
System Engineers and IntegratorsEstablished - 1988
Services- Design and Engineering - Feasibility Studies- Systems Integration- Installation- Commissioning - Consulting - Distributors
Systems- Batching Systems- SCADA - Field bus Systems- Control and Automation- Tracking Systems (Since January 2000)
MIRTEC TECHNOLOGIESMIRTEC TECHNOLOGIES
Industry- Coal Fired Power Generation.
- Platinum,Gold and Chrome Mining and Refineries.
- Pulp and Paper.
- Automotive.
- Petro-Chemical.
- Food and Beverage.
- Material Handling
Future- Radio Frequency Identification
Industry- Coal Fired Power Generation.
- Platinum,Gold and Chrome Mining and Refineries.
- Pulp and Paper.
- Automotive.
- Petro-Chemical.
- Food and Beverage.
- Material Handling
Future- Radio Frequency Identification
MIRTEC TECHNOLOGIESMIRTEC TECHNOLOGIES
Location
Durban South AfricaMajor Industrial City and Port Situated on the East Coast.
Location
Durban South AfricaMajor Industrial City and Port Situated on the East Coast.
OfficesOffices Map RelationMap Relation
EmployeesEmployees
Total 18 employees consisting of System Analyst's, Engineers and Field Technicians. Total 18 employees consisting of System Analyst's, Engineers and Field Technicians.
MIRTEC TECHNOLOGIESMIRTEC TECHNOLOGIES
DurbanDurban
Geographical CoverageGeographical Coverage
Main PortMain Port
MIRTEC TECHNOLOGIESMIRTEC TECHNOLOGIES
DurbanDurban
Port ElizabethPort Elizabeth
Automotive Industry
Automotive Industry
Geographical CoverageGeographical Coverage
Main PortMain Port
MIRTEC TECHNOLOGIESMIRTEC TECHNOLOGIES
JohannesburgJohannesburg
Industrial CapitalIndustrial CapitalGeographical CoverageGeographical Coverage
DurbanDurban
Port ElizabethPort Elizabeth
Automotive IndustryAutomotive Industry
Main PortMain Port
MIRTEC TECHNOLOGIESMIRTEC TECHNOLOGIES
Cape TownCape Town
Agricultural Sector Agricultural Sector
Geographical CoverageGeographical CoverageJohannesburgJohannesburg
Industrial CapitalIndustrial Capital
DurbanDurban
Port ElizabethPort Elizabeth
Automotive IndustryAutomotive Industry
Main PortMain Port
MIRTEC TECHNOLOGIESMIRTEC TECHNOLOGIES
Cape TownCape Town
Agricultural Sector Agricultural Sector
Geographical CoverageGeographical Coverage
AfricaAfrica
FutureFuture
JohannesburgJohannesburg
Industrial CapitalIndustrial Capital
DurbanDurban
Port ElizabethPort Elizabeth
Automotive IndustryAutomotive Industry
Main PortMain Port
THE COMPANYTHE COMPANY
SA ManufacturingSA Manufacturing
• Founded 1961
• Importer, Assembler, Manufacturer and Marketer of Motor Vehicles,and Motor
Vehicle Parts and Accessories.
• Also has the agency for Hino Trucks
• 6700 Employees
• 6 Billion Rands ($860 Million) Turnover
• Market Leader for the last 21 years – Presently 24% of South Africa Market
Share
• Future plans to export to Australia – Therefore working towards WCM (World
Class
Manufacturing)
• Plant Production capacity - 500 Vehicles per 8hr shift.
• Current Production – 360 Vehicles per shift (96 400 per Annum).
• Manufacture 6 Models
– Tazz, Corolla, Camry, Condor, Hi-Lux(Pick Up), Hi-Ace (Mini Bus Transporter)
• Founded 1961
• Importer, Assembler, Manufacturer and Marketer of Motor Vehicles,and Motor
Vehicle Parts and Accessories.
• Also has the agency for Hino Trucks
• 6700 Employees
• 6 Billion Rands ($860 Million) Turnover
• Market Leader for the last 21 years – Presently 24% of South Africa Market
Share
• Future plans to export to Australia – Therefore working towards WCM (World
Class
Manufacturing)
• Plant Production capacity - 500 Vehicles per 8hr shift.
• Current Production – 360 Vehicles per shift (96 400 per Annum).
• Manufacture 6 Models
– Tazz, Corolla, Camry, Condor, Hi-Lux(Pick Up), Hi-Ace (Mini Bus Transporter)
PLANT LAYOUT & PROCESS FLOWPLANT LAYOUT & PROCESS FLOW
Body ShopBody Shop Paint ShopPaint Shop Assembly HallAssembly Hall Vehicle Final Line Vehicle Final Line
TOYOTA SAMARKETING (TSB)
TOYOTA SAMARKETING (TSB)
Distribution Yards Distribution Yards
A Yard A Yard
B Yard B Yard
Train Train
TOYOTA SA MANUFACTURING (TSM)
TOYOTA SA MANUFACTURING (TSM)
PLANT LAYOUT & PROCESS FLOWPLANT LAYOUT & PROCESS FLOW
Body ShopBody Shop Paint ShopPaint Shop Assembly HallAssembly Hall Vehicle Final Line Vehicle Final Line
TOYOTA SAMARKETING(TSB)
TOYOTA SAMARKETING(TSB)
Distribution Yards Distribution Yards
A Yard A Yard
B Yard B Yard
Train Train
TOYOTA SA MANUFACTURING(TSM)
TOYOTA SA MANUFACTURING(TSM)
PLANT LAYOUT & PROCESS FLOWPLANT LAYOUT & PROCESS FLOW
Body ShopBody Shop Paint ShopPaint Shop Assembly HallAssembly Hall Vehicle Final Line Vehicle Final Line
TOYOTA SAMARKETING(TSB)
TOYOTA SAMARKETING(TSB)
Distribution Yards Distribution Yards
A Yard A Yard
B Yard B Yard
Train Train
TOYOTA SA MANUFACTURING(TSM)
TOYOTA SA MANUFACTURING(TSM)
PLANT LAYOUT & PROCESS FLOW
Body ShopBody Shop Paint ShopPaint Shop Assembly HallAssembly Hall Vehicle Final Line Vehicle Final Line
TOYOTA SAMARKETING(TSB)
TOYOTA SAMARKETING(TSB)
Distribution Yards Distribution Yards
A Yard A Yard
B Yard
Train Train
TOYOTA SA MANUFACTURING(TSM)
TOYOTA SA MANUFACTURING(TSM)
PLANT LAYOUT & PROCESS FLOWPLANT LAYOUT & PROCESS FLOW
Body ShopBody Shop Paint ShopPaint Shop Assembly HallAssembly Hall Vehicle Final Line Vehicle Final Line
TOYOTA SA MANUFACTURING(TSM)
TOYOTA SA MANUFACTURING(TSM)
TOYOTA SAMARKETING(TSB)
TOYOTA SAMARKETING(TSB)
Distribution Yards Distribution Yards
A Yard A Yard
B Yard B Yard
Train Train
PLANT LAYOUT & PROCESS FLOWPLANT LAYOUT & PROCESS FLOW
Body ShopBody Shop Paint ShopPaint Shop Assembly HallAssembly Hall Vehicle Final Line Vehicle Final Line
TOYOTA SA MANUFACTURING(TSM)
TOYOTA SA MANUFACTURING(TSM)
TOYOTA SAMARKETING(TSB)
TOYOTA SAMARKETING(TSB)
Distribution Yards Distribution Yards
A Yard A Yard
B Yard B Yard
Train Train
PLANT LAYOUT & PROCESS FLOWPLANT LAYOUT & PROCESS FLOW
Body ShopBody Shop Paint ShopPaint Shop Assembly HallAssembly Hall Vehicle Final Line Vehicle Final Line
TOYOTA SA MANUFACTURING(TSM)
TOYOTA SA MANUFACTURING(TSM)
TOYOTA SAMARKETING(TSB)
TOYOTA SAMARKETING(TSB)
Distribution Yards Distribution Yards
A Yard A Yard
B Yard B Yard
Train Train
PLANT LAYOUT & PROCESS FLOWPLANT LAYOUT & PROCESS FLOW
Body ShopBody Shop Paint ShopPaint Shop Assembly HallAssembly Hall Vehicle Final Line Vehicle Final Line
TOYOTA SA MANUFACTURING(TSM)
TOYOTA SA MANUFACTURING(TSM)
TOYOTA SAMARKETING(TSB)
TOYOTA SAMARKETING(TSB)
Distribution Yards Distribution Yards
A Yard A Yard
B Yard B Yard
Train Train
PLANT LAYOUT & PROCESS FLOWPLANT LAYOUT & PROCESS FLOW
Body ShopBody Shop Paint ShopPaint Shop Assembly HallAssembly Hall Vehicle Final Line Vehicle Final Line
TOYOTA SA MANUFACTURING(TSM)
TOYOTA SA MANUFACTURING(TSM)
TOYOTA SAMARKETING(TSB)
TOYOTA SAMARKETING(TSB)
Distribution Yards Distribution Yards
A Yard A Yard
B Yard B Yard
Train Train
COMPANY REQUIREMENTSCOMPANY REQUIREMENTS
• Due to the introduction of SAP into TOYOTA , it was realized that an Automatic Tracking System had to be implemented. The main reason being to ensure Real Time WIP (Work In Progress) information for use on the shop floor, stock control and Financial Management
• To achieved this the ultimate objective would be to have the Auto Tracking operational from the start of the production process (Body Shop) through to Vehicle Distribution throughout the country.
• Due to the introduction of SAP into TOYOTA , it was realized that an Automatic Tracking System had to be implemented. The main reason being to ensure Real Time WIP (Work In Progress) information for use on the shop floor, stock control and Financial Management
• To achieved this the ultimate objective would be to have the Auto Tracking operational from the start of the production process (Body Shop) through to Vehicle Distribution throughout the country.
HISTORYHISTORY
• Job cards Processed Manually.
• Vehicles moved no faster than the paper work flow.
• Fitment and distribution planning was done only on what had physically reached a workstation. With a result - no forward planning.
• Stock holding in the Distribution Yards was 3 days due to manual paper work processing.
• NO REAL TIME DATA!!!!!
• Job cards Processed Manually.
• Vehicles moved no faster than the paper work flow.
• Fitment and distribution planning was done only on what had physically reached a workstation. With a result - no forward planning.
• Stock holding in the Distribution Yards was 3 days due to manual paper work processing.
• NO REAL TIME DATA!!!!!
PROJECT PHASES PROJECT PHASES
Toyota’s decision was to introduce an Auto Radio Frequency ID Tracking System within the plant and implement this in two phases.
• Phase 1 – Paint Shop (Dollies and Hangers)
– Dual purpose installation
- Tracking of Vehicles
- Tracking of Vehicle Carriers for maintenance purposes
• Phase 2 – Complete Process
Fixed RF Tag on the vehicle throughout overall process
capable of withstanding harsh paint shop environment.
Toyota’s decision was to introduce an Auto Radio Frequency ID Tracking System within the plant and implement this in two phases.
• Phase 1 – Paint Shop (Dollies and Hangers)
– Dual purpose installation
- Tracking of Vehicles
- Tracking of Vehicle Carriers for maintenance purposes
• Phase 2 – Complete Process
Fixed RF Tag on the vehicle throughout overall process
capable of withstanding harsh paint shop environment.
PHASE 1PHASE 1
50°c – 55 °c50°c – 55 °c
50°c – 55 °c
50°c – 55 °c50°c – 55 °c
50°c – 55 °c
DiptankDiptankSprayDiptankSpray30 °CSpray cold water
DiptankDiptankSprayDiptankSpray30 °CSpray cold water
- Pre-degrease- Degrease 2 - Water Rinse 1- Zinc Phosphate- Demineralized Water Rinse- E-Coated at 300 VDC Electrolytic - Rinse
- Pre-degrease- Degrease 2 - Water Rinse 1- Zinc Phosphate- Demineralized Water Rinse- E-Coated at 300 VDC Electrolytic - Rinse
TempTempMethodMethodHangers – Process DataHangers – Process Data
Cycles : 1.09 per day – 288 per annumCycles : 1.09 per day – 288 per annum
PHASE 1PHASE 1
195 °c 180 °c 170 °c 165 °c
215 °c 165 °c
195 °c 180 °c 170 °c 165 °c
215 °c 165 °c
8 mins8 mins8 mins8 mins
15 mins15 mins
8 mins8 mins8 mins8 mins
15 mins15 mins
Primer ovens 1-4 - Oven Zones 1- Oven Zone 2- Oven Zone 3- Oven Zone 4
Colour ovens- Oven Zones 1- Oven Zone 2
Primer ovens 1-4 - Oven Zones 1- Oven Zone 2- Oven Zone 3- Oven Zone 4
Colour ovens- Oven Zones 1- Oven Zone 2
TempTempDurationDurationDOLLIES – Process DataDOLLIES – Process Data
Cycles : 2.13 per day – 563 per annumCycles : 2.13 per day – 563 per annum
PHASE 1PHASE 1
Products UsedProducts Used
13.5MHz International standardized frequency13.5MHz International standardized frequency
PHASE 1PHASE 1
Products Used• RF Tags - HMS 150 HT - Quantity 500
Products Used• RF Tags - HMS 150 HT - Quantity 500
13.5MHz International standardized frequency13.5MHz International standardized frequency
PHASE 1PHASE 1
RF Tags - HMS 150 HT- Passive (No Batteries)
- Read/Write
- 736 bytes memory
- Baud Rate 9600
- -40 °C to 240 °C
- Reusable
- NEMA 6P/13(IP 68)
RF Tags - HMS 150 HT- Passive (No Batteries)
- Read/Write
- 736 bytes memory
- Baud Rate 9600
- -40 °C to 240 °C
- Reusable
- NEMA 6P/13(IP 68)
PHASE 1PHASE 1
Products Used• RF Tags - HMS 150 HT
- Quantity 500
• RF Readers– HMS 820
- Quantity 14
Products Used• RF Tags - HMS 150 HT
- Quantity 500
• RF Readers– HMS 820
- Quantity 14
13.5MHz International standardized frequency13.5MHz International standardized frequency
PHASE 1PHASE 1
RF Readers– HMS 820 - Integrated Antenna
- 4 Input/Output points
- Host Interface (Com 1)
-RS232/RS422/MUX 32
- Auxiliary RS232 serial port.
- 1000 bytes/sec transfer speed.
- NEMA 4 (IP 66)
RF Readers– HMS 820 - Integrated Antenna
- 4 Input/Output points
- Host Interface (Com 1)
-RS232/RS422/MUX 32
- Auxiliary RS232 serial port.
- 1000 bytes/sec transfer speed.
- NEMA 4 (IP 66)
PHASE 1PHASE 1
Products Used• RF Tags - HMS 150 HT
- Quantity 500
• RF Readers– HMS 820
- Quantity 14
• Interface module – MM80
- Quantity 1
Products Used• RF Tags - HMS 150 HT
- Quantity 500
• RF Readers– HMS 820
- Quantity 14
• Interface module – MM80
- Quantity 1
13.5MHz International standardized frequency13.5MHz International standardized frequency
PHASE 1PHASE 1
MM80 MicroMux – Bus module- RS232/RS485 converter
- Mux 32 protocol
- C programmable
- 9600 & 346K baud communication
- Network up to 32 devices
MM80 MicroMux – Bus module- RS232/RS485 converter
- Mux 32 protocol
- C programmable
- 9600 & 346K baud communication
- Network up to 32 devices
PHASE 1PHASE 1
Software and Interface• In-house Custom Written Software • Visual C++
Software and Interface• In-house Custom Written Software • Visual C++
PHASE 1PHASE 1
Software and Interface- 2 Alternate interfaces- RS232 to Token Ring Thin Client (VTS)- RS485 (Mux 32) to EMS Data base
(Maintance)
Software and Interface- 2 Alternate interfaces- RS232 to Token Ring Thin Client (VTS)- RS485 (Mux 32) to EMS Data base
(Maintance)
REV. DESCRIPTION DATE BY DRAWN
APPR'D
SCALE
TITLE:
PROJECT:
DWG NO:
SHT No
DATEMIRTEC TECHNOLOGIES
P.O.BOX 20161
DURBAN NORTH,4016
TEL:(031) 5636611
FAX:(031)5635433
21 3 4 5 6 7
1011 9 812
RS232
041 044A 44B 048042
035A 035B 037 040 045A 045B
MM 80
034READER STATION ID.
THIN CLIENT
EMS READER
RFID/P001/TSM/201
RFID READER NETWORK
RS485 MULTIDROP
TOYOTA - PAINT SHOP VTS
RFID -CPOI
MUX ADDRESS0
001
13
030
01 READ STATION 001 ADDED
MAINT.PC MOVED
11.00 KO'N
PHASE 1PHASE 1
Duration & Value
- Total Project 12 weeks
- Cost R600 000($85 000)
Duration & Value
- Total Project 12 weeks
- Cost R600 000($85 000)
PHASE 2PHASE 2
• Description
Tracking of Vehicles.
96 400 Units per annum.
• Description
Tracking of Vehicles.
96 400 Units per annum.
PHASE 2PHASE 2
• Description
Tracking of Vehicles.
96 400 Units per annum.
• Description
Tracking of Vehicles.
96 400 Units per annum.
PHASE 2PHASE 2
• Criteria
- 6 different models.
- No common mounting position.
- Withstand Harsh conditions (200°c).
- Cost < R35 ($5) per Tag.
• Criteria
- 6 different models.
- No common mounting position.
- Withstand Harsh conditions (200°c).
- Cost < R35 ($5) per Tag.
PHASE 2PHASE 2
Products UsedProducts Used
13.5MHz International standardized frequency13.5MHz International standardized frequency
PHASE 2PHASE 2
Products Used• RF Tags – LRP 250 HT-FLX - Quantity 96 400 per annum
Products Used• RF Tags – LRP 250 HT-FLX - Quantity 96 400 per annum
13.5MHz International standardized frequency13.5MHz International standardized frequency
PHASE 2PHASE 2
RF Tags - LRP 250 HT-FLX- Passive (No Batteries)
- Read/Write
- 48 bytes memory
- Reusable or Disposable
- Adhesive backing
- -40 °c to 240 °c
- NEMA 6P/13(IP 68)
RF Tags - LRP 250 HT-FLX- Passive (No Batteries)
- Read/Write
- 48 bytes memory
- Reusable or Disposable
- Adhesive backing
- -40 °c to 240 °c
- NEMA 6P/13(IP 68)
PHASE 2PHASE 2
Products Used• RF Tags – LRP 250 HT-FLX
- Quantity 96 400 per annum
• RF Readers– LRP 820-08
- Quantity 71
Products Used• RF Tags – LRP 250 HT-FLX
- Quantity 96 400 per annum
• RF Readers– LRP 820-08
- Quantity 71
13.5MHz International standardized frequency13.5MHz International standardized frequency
PHASE 2PHASE 2
RF Readers– LRP 820-08 - Read/Write multiple tags
simultaneously
- 4 Input/Output points
- Host Interface (Com 1)
-RS232/RS422/MUX 32
- Auxiliary RS232 serial port.
- NEMA 4 (IP 66)
RF Readers– LRP 820-08 - Read/Write multiple tags
simultaneously
- 4 Input/Output points
- Host Interface (Com 1)
-RS232/RS422/MUX 32
- Auxiliary RS232 serial port.
- NEMA 4 (IP 66)
PHASE 2PHASE 2
Products Used• RF Tags – LRP 250 HT-FLX - Quantity 96 400 per annum • RF Readers– LRP 820-08 - Quantity 71• Portable reader – Formula 7400 - Quantity 5
Products Used• RF Tags – LRP 250 HT-FLX - Quantity 96 400 per annum • RF Readers– LRP 820-08 - Quantity 71• Portable reader – Formula 7400 - Quantity 5
13.5MHz International standardized frequency13.5MHz International standardized frequency
PHASE 2PHASE 2
Portable reader – Formula 7400
- I.Code Identification
- Read RFID and Barcodes.
- Based on a 486 processor.
- Integrated full RS232 and IrDA Ports
Portable reader – Formula 7400
- I.Code Identification
- Read RFID and Barcodes.
- Based on a 486 processor.
- Integrated full RS232 and IrDA Ports
PHASE 2PHASE 2
Products Used• RF Tags – LRP 250 HT-FLX - Quantity 96 400 per annum • RF Readers– LRP 820-08 - Quantity 71• Portable reader – Formula 7400 - Quantity 5• Pass through Gate Antenna - Quantity 1• Interface module – MM80 - Quantity 9
Products Used• RF Tags – LRP 250 HT-FLX - Quantity 96 400 per annum • RF Readers– LRP 820-08 - Quantity 71• Portable reader – Formula 7400 - Quantity 5• Pass through Gate Antenna - Quantity 1• Interface module – MM80 - Quantity 9
13.5MHz International standardized frequency13.5MHz International standardized frequency
PHASE 2PHASE 2
Software and Interface• RS232 interface with Token Ring Thin Client within TSM Production Plant.
• RS485 Multi drop Network throughout TSB Distribution Yards.Interfaced to TSM via Token Ring Gateway.
• Wonderware IN-TRACK software.
• SAP Management System
Software and Interface• RS232 interface with Token Ring Thin Client within TSM Production Plant.
• RS485 Multi drop Network throughout TSB Distribution Yards.Interfaced to TSM via Token Ring Gateway.
• Wonderware IN-TRACK software.
• SAP Management System
PHASE 2PHASE 2
Duration & Value(Excluding Software and Token Ring Network)
- Total Project 6 months
- Cost R1.6 million ($230 000)
- Tags monthly consumable.
Duration & Value(Excluding Software and Token Ring Network)
- Total Project 6 months
- Cost R1.6 million ($230 000)
- Tags monthly consumable.
COSTS & BENEFITSCOSTS & BENEFITS
• Phase 2
Overall Vehicle Tracking Project - R9 500 000 ($1.357 000)
- Manual data capture – redundant - Real Time/Work In Progress information available.
- Reduction of Stockholding.
“ONE DAY STOCK REDUCTION EQUATES TO R35 ($7)
SAVING PER UNIT IN FINANCING COSTS”
96 400 Units per annum @ R35 = R3 374 000 ($482 000)
• Phase 2
Overall Vehicle Tracking Project - R9 500 000 ($1.357 000)
- Manual data capture – redundant - Real Time/Work In Progress information available.
- Reduction of Stockholding.
“ONE DAY STOCK REDUCTION EQUATES TO R35 ($7)
SAVING PER UNIT IN FINANCING COSTS”
96 400 Units per annum @ R35 = R3 374 000 ($482 000)
COMPETITORSCOMPETITORS
• Siemens
• Baumer Ident
• Impro (SA)
– First two competitors products very expensive
– Third competitor products failed during trials
• Siemens
• Baumer Ident
• Impro (SA)
– First two competitors products very expensive
– Third competitor products failed during trials
CONCLUSIONCONCLUSION
• It is believed that this VTS project will
move TOYOTA towards World Class
Manufacturing.
• It is believed that this VTS project will
move TOYOTA towards World Class
Manufacturing.