TOYOTA Shop Floor Application Presented by: Kevin O’Neil Presented by: Kevin O’Neil.

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


• Costs & Benefits

• Competitors

• Conclusion

• Q&A

• Application



• Costs & Benefits

• Competitors

• Conclusion

• Q&A

Company Details

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


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.


Geographical CoverageGeographical Coverage


DurbanDurban


Main PortMain Port


DurbanDurban

Port ElizabethPort Elizabeth

Automotive Industry

Automotive Industry


Main PortMain Port


JohannesburgJohannesburg

Industrial CapitalIndustrial CapitalGeographical CoverageGeographical Coverage

DurbanDurban


Automotive IndustryAutomotive Industry

Main PortMain Port


Cape TownCape Town

Agricultural Sector Agricultural Sector

Geographical CoverageGeographical CoverageJohannesburgJohannesburg

Industrial CapitalIndustrial Capital

DurbanDurban



Main PortMain Port


Cape TownCape Town

Agricultural Sector Agricultural Sector


AfricaAfrica

FutureFuture

JohannesburgJohannesburg

Industrial CapitalIndustrial Capital

DurbanDurban



Main PortMain Port

Project Details

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)



TOYOTA SAMARKETING(TSB)



A Yard A Yard

B Yard B Yard

Train Train

TOYOTA SA MANUFACTURING(TSM)


PLANT LAYOUT & PROCESS FLOW





A Yard A Yard

B Yard

Train Train










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

• Tag Mounting - HANGERS -

DOLLIES

• Tag Mounting - HANGERS -

DOLLIES

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


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


- Quantity 500


- Quantity 14


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



-RS232/RS422/MUX 32


- 1000 bytes/sec transfer speed.

- NEMA 4 (IP 66)

PHASE 1PHASE 1


- Quantity 500


- Quantity 14

• Interface module – MM80

- Quantity 1


- Quantity 500


- Quantity 14

• Interface module – MM80

- Quantity 1


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

• 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


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


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


PHASE 2PHASE 2

RF Readers– LRP 820-08 - Read/Write multiple tags

simultaneously



-RS232/RS422/MUX 32


- NEMA 4 (IP 66)

RF Readers– LRP 820-08 - Read/Write multiple tags

simultaneously



-RS232/RS422/MUX 32


- 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


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


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.

Q & AQ & A

??

TOYOTA Shop Floor Application Presented by: Kevin O’Neil Presented by: Kevin O’Neil.

Documents

Transcript of TOYOTA Shop Floor Application Presented by: Kevin O’Neil Presented by: Kevin O’Neil.