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© MothersonSumi INfotech and Designs Ltd. A CMM Level 5 Company

C & C System Over View Harness

General TerminologyManufacturing StepsC & C SystemSub System Overview


General Terminology

What is Harness ?

Harness is a composite electric circuit of automobile. It works as nervous system of a vehicle

Harness Operations Cut & Crimp

Cut

Crimp

Splice

Part Fitting

Sub Assembly

Assembly

Inspection

Packing & Dispatch


APPLICATION OVER VIEW

This system computerizes Wire Harness manufacturing and integrates the manufacturing process such as C&C production schedule, Optimization process, lead wire C&C instruction and C&C production output.

PURPOSE OF THE SYSTEM DEVELOPMENT Improvement of control accuracy

Reduction of the office work load

Reduction of manual operation time

Stable manufacturing

The best operation instruction

Introduction of C&C


International

VAN Terminal

C&C Server

C&C ClientsLaser Printer

C&C System

System Composition

Komax Networked Machine


C&C SYSTEM (Network Overview)

C&C Server(SQL Server 2K)

LeadStores

HP LaserJet 8150

C&C ClientPDT

BarcodeScanner

C&CPlanner

C&C Client & WPCS Format

Generator

HP LaserJet 8150 TEC PRINTER

(For EFU Tkt)

C&C Client

LAN

WPCS Enabled Wire processing

machines

DHS Server(SQL Server 2K)


Sub System Over View

1. Send & Receive Data Sub System2. BOM Maintenance Sub System3. C & C Daily Production Schedule (CPS) Sub System 4. Optimization Sub System5. Production Output Report Sub System6. Master Files Maintenance Sub System7. CUP Sub System 8. Stock Taking Sub System9. GBG Sub System

This system consist of following modules


Send & Receive Data Sub System provide the functions to get BOM data and to import to the C&C system.

Send & Receive Data Sub System

BOM -: Bill Of Material for C&C System is the data prepared by SWS for design of new products.

B O M D ata H e ig h t D a ta

B O M fo r C & C S ys tem


BOM List Of Not Set Height

C&C Clients

List of not set MachineNo.

Wire Type Change List

New Wire List

New Terminal List

New Material List

BOM Upload List

BOM Upload Error List

ProductBOM

SpliceBOM

MaterialDetail BOM

MHBOM

MaterialBOM

CircuitBOM

CircuitGrp Detail

Terminal

Material

SetMachine No

Height

BOM


Ｏ DENGRP.TXT ＮＣＰＳ

Height Upload List

Height

ＷＯＮＣＰＳ

CircuitBOM

LocalHeight

CKYOZKN.TXT

TANZKN.TXT

HGTKAN.TXT

Height Upload


BOM Maintenance Sub System

BOM Maintenance is to add some production condition (Ex Machine Condition)

BOM data can be displayed, modified, added, deleted and copied.

BOM related Lists are displayed. (Circuit BOM List, Terminal Usage List and so on.


Output Report for BOM sub system

Report Name Report Explanation

Product BOM List When you want to confirm the Product BOM, use this list.

Circuit BOM List When you want to confirm the Circuit BOM, use this list.

Wire Requirement List When you want to check the ‘Wire Requirement’ per all product No / specific product No / CPS , use this list.

Terminal Requirement List

When you want to check the ‘Terminal Requirement’ per all product No / specific product No / CPS , use this list.

Terminal Usage List When you want to check the ‘Terminal Combination Pattern’ per all product No / specific product No / CPS , use this list.

Wire & Teminal Usage List

When you want to check the ‘Wire & Terminal Combination Pattern’ per all product No / specific product No / CPS , use this list.

Material Requirement List

When you want to check the ‘Material Requirement’ per all product No / specific product No / CPS , use this list.


C & C Daily Production Schedule (CPS) Sub System

Production Schedule

C&C Schedule

ProductionSchedule List List

1

4

7

2

5

8

3

6

(1)

(2)

(3)Output CPS ReportCPS Arrangement

The Registration of C&C schedule is necessary to keep the C&C System based on the production schedule.

CPS Sub System includes the function to register the C&C schedule for scheduling staff according to customer purchase order.

C&C start date and issue date

You should input issue date every “Lot No” or “Work Order No” when you register the C&C schedule.

Each C&C start date and short code is set by C&C system automatically.

Decision of C&C start date

You can specify the L/T in every process pattern.* L/T abbreviation for “Lead Time”.

Single Wire L/T

Splice processing L/T

Non Single Wire processing L/T (Pre Insert, Manual Crimping)

Special Wire L/T


How to get a start date in each process(1). Single Wire L/T = Single Wire L/T(2). Splice Wire L/T = Single Wire L/T + Splice processing L/T(3). Non Single Wire L/T = Single Wire L/T + Non Single processing L/T(4). Special Wire L/T = Special Wire L/T(Ex.) 1. Single Wire L/T 1 day 2. Splice processing L/T 1 day 3. Non Single Wire processing L/T 2 days 4. Special Wire L/T 4 days

Issue Date Nov 15

Nov 11th Nov 12th Nov 13th Nov 14th Issue Date

Single Wire 1Splice Wire 1 2 Non Single Wire 1 2 3Special Wire 4

CPS Sub System


Optimization Sub System

BOM

EFU ExtractionCheck List

12

3

(1) EFU Extraction

(2) Optimization

(3) Machine working loadArrangement

CPS Data

4

EFU

(4) Report Output

The brief of Optimization Sub System is as the follows.

Daily working data is extracted from CPS data and after optimization EFU data is prepared.

EFU data is ordered in consideration of change time or EFU No or Process Pattern.

Optimization related reports are available. (Daily Working Report, Work Load List and so on


Manual OptimizationYou can arrange the auto optimization result manually.Moving inside the same machineThe order change on the specific machineMoving between the machinesEFU data moving between the specific machines

Optimization Sub System

Work Load List

Work Load Detail List

C&C Instruction Sheet

Lead Set-up report

Daily Working Report

Wire Requirement List

Wire Preparation List

Terminal Requirement List

Terminal Preparation List

Material Requirement List

EFU Sheet (Normal)

EFU Sheet (Emergency)

This list is to confirm the man-hour and set-up time and production quantity per shift and machine.

(This list is used for machine working load arrangement.)

This list is to confirm the circuit information and man-hour and set-up time and production quantity per shift and machine.

(This list is used for machine working load arrangement.)

EFU

This is a daily report to fill the EFU order and defect information and actual height information.

This list is used for wire preparation.

Wire type, wire size, wire flex, production quantity is outputted.

This list is used for wire preparation.

Wire type, wire size, wire flex and production quantity is outputted per machine..

This list is used for terminal preparation.

Directions sheet for C&C operator.

This is EFU for emergency.

Specify the product no and circuit, and output the EFU one by one.


Production Output Report Sub System

Daily WorkingReport

(1) Input Actual Result

EFU HalfTicket

(1) Refer to the Actual Result

Progress Status Screen

You Input actual C&C result of operator by the Daily Working Report.You register actual C&C result of EFU by using barcode reader.

Refer to the C&C completion status on the C&C status screen if necessary.

Output Reports are as follows.

1.SKT List

2.Efficiency List(per M/C or per Operator)

3.Defect List

Status Enquiry is obtained along with the information details regarding the

A. Circuit giving Terminal as well as Material Description

B . Defect giving the defect quantities corresponding to the defect

codes

4.Machine Maintenance List

5. Daily Working Report


Master Files Maintenance Sub System

We must adjust some manufacture conditions again in this sub system when produces the new product or introduce a new auto C&C machine and so on

Standards of the factory can be decided.

Standards of machine can be decided.

Access limit of user can be decided.

(Standard Data) Capacity of factor C&C Machine OperatorTerminal Wire

Standard Tables

(1) Input the standard data

Machine Cutting (Type/Size)Manual Cutting (Wire Length)TerminalMaterialApplicatorPre-Ins MaterialWire Bunch ClassWire Bunch ConditionProcessMachine NoMachine SettingMachine ConditionCircuit ConditionWire Bunch SizeUnnecessary BOM dataChange Wire TypeWireCalendarLead TimeSerial NoOperatorDefect CodeSpoilage CodeM/C Std Run TimeHeight Check ScreenO/H TerminalTerminal RetentionLocal HeightUser IDPGM FunctionPGM Function RelationFunction CTL

BOM

Others

Process Decision

Machine Decision

Others

Working DayLead Time Operator Name

User ID/NamePGM ID/NameUser and PGM RelationSystem Function Control

Send & Receive data Sub System

CPS Sub System

POR Sub System

Height Relation

System


CUP Sub System

Purpose of the CUP subsystem is to introduce an imaginary product using multiple Products which have similar circuit Information common at different level.Common Product is a combination of products which share some common circuit information.Products which share some common circuit information and combine together form a common product, are called component product.

Advantages of CUP SystemNumber of EFU’s can be reduced and production quantity for each lot can be increased.The setup time (Changeover Time) will be reduced.C&C production efficiency will be better.

Product #A Product #B

Product #C

Common Circuits in Product #B & #C

Common Circuits in Product #B & #A

Common Circuits in Product #A & #C

Common Circuits in Product #A, B & #C

Common Product


Stock Taking Sub System

This subsystem can support the stocktaking job for C&C area.Prints the stocktaking check sheet.Staffs for stocktaking fill this check sheet with circuit or material quantity in C&C area.There are 4 method for filling the check sheet. Circuit Group and quantity Circuit and quantity EFU Serial No and quantity Circuit and material quantity


GBG Subsystem

Unnecessary data that it passed through the specified term is exported to text file and compress. After this, these data is deleted from C&C database.


To meet the requirements of SEWS-E (Sumitomo Electric Wiring System Europe) following 2 modules has been added in the Standard C&C System.

Module: 1• STOCK CONTROL SYSTEM

( SEWS-E system )

Module: 2• MRP SUBSYSTEM

( SEWS-E system )

SEWS-E C&C (System Overview)


SWS/UK HEIGHT DATA

I.H.S CADDATA

LESZNO DEVA TOPOLCANYRAWICZ

CUTTINGMACHINE

ORASTIE

ENGDEPT

ENGDEPT

ENGDEPT

ENGDEPT

ENGDEPT

MACHINENETWORK

MACHINENETWORK

MACHINENETWORK

MACHINENETWORK

MACHINENETWORK

CUTTINGMACHINE

CUTTINGMACHINE

CUTTINGMACHINE

CUTTINGMACHINE

LOCALMRP

&LEADS STOCK

SYSTEM

ASSEMBLY

C&CSYSTEM

C&CSYSTEM

C&CSYSTEM

C&CSYSTEM

C&CSYSTEM

SEWS-E C&C (System Overview)

ALBA

ENGDEPT

MACHINENETWORK

CUTTINGMACHINE

C&CSYSTEM


ASSEMBLYPLANNING

ENGINEERING

I.H.SC.A.D

HEIGHT DATA

CST PROCESSES

StandardC&C

System

MPSDATA

PRODUCTB.O.M.s

HEIGHTDATA

MACHINENETWORK

D.H.S MPS

MACHINE TYPE DATACIRCUIT BOM DATA

STOCK DATAMRP RESULT

MACHINE OPTIMISATION DATATICKET DATA

MACHINE NETWORK DATABUILD SCHEDULES

C&C SYSTEM

LEAD STORESTOCK

SYSTEM

ASSEMBLY

ALSO NONNETWORKMACHINES

SEWS-E C&C (Data Flow)


C&C Assembly CPS

MRPCut Lead Stock Build Schedule(Planned qty )

Safety Stock

DecreaseIncrease

DHS Assembly MPS

CC masterfile CC optimisation

Order PolicyModifiers ( LT / Calendar etc )

Availability Reports

Decrease

Daily working report & Tickets

MRP CheckReport

LEAD STORES

C&C PROCESS

Suggested CuttingSchedules After MRP

BOOK IN

BOOK OUT

KITTING

BUILD SCHEDULES

SEWS-E C&C (Stock/MRP Logic)


SEWS-E C&C (MRP Suggestion)MRP Suggestions As on >> 10/02/03 <<

Common Product or Product Number : TOYDRLH ( example )

Bundle Qty MRP Suggestions

A Side B Side BECC CCVC 10/02/2003 17/02/2003 24/02/2003 Safety Stock Arrears Current Future 1 Week 1 Week 17/02/2003

#PO P79 0 60 240 240 240 60 0 0 240 0 240 60 240#R1 JAV 0 60 240 240 240 60 0 0 240 0 240 60 240$NE JAT 0 60 240 240 240 60 0 0 240 0 240 60 240$NL JAU 0 60 240 240 240 60 0 0 240 0 240 60 240$QE Q43 0 60 240 240 240 60 0 0 240 0 240 60 240$QT Q17 0 60 480 480 480 60 0 0 480 0 480 60 480$QU Q18 0 60 480 480 480 60 0 0 480 0 480 60 480%Z3 #ZE 0 60 240 240 240 60 0 0 240 0 240 60 240%Z3 &EA 0 60 360 360 360 60 0 0 360 0 360 60 360%Z3 JAW 0 60 240 240 240 60 0 0 240 0 240 60 240%Z3 Z62 0 60 240 240 240 60 0 0 240 0 240 60 240%Z3 ZHU 0 60 240 240 240 60 0 0 240 0 240 60 240*1 *2 0 60 480 480 480 60 0 0 480 0 480 60 480JJJ PM1 0 60 240 240 240 60 0 0 240 0 240 60 240JJJ PM4 0 60 240 240 240 60 0 0 240 0 240 60 240JJJ PMZ 0 60 240 240 240 60 0 0 240 0 240 60 240P64 P80 0 60 240 240 240 60 0 0 240 0 240 60 240P65 P81 0 60 240 240 240 60 0 0 240 0 240 60 240PNK PNM 0 60 240 240 240 60 0 0 240 0 240 60 240PP4 PMW 0 60 240 240 240 60 0 0 240 0 240 60 240R47 R86 0 60 480 480 480 60 0 0 480 0 480 60 480R48 R52 0 60 480 480 480 60 0 0 480 0 480 60 480

0 0 6600 0 6600 1100 66000 0 2400 0 2400 400 24000 0 1440 0 1440 300 14400 0 2760 0 2760 400 27600 0 6600 0 6600 1100 6600

868

22Total Sub Circuits Total Circuits

Sub Circuits QuantityGrand Total

Total Single CircuitsTotal Splice Circuits

Past Due Suggestions

Total QuantitySingle Circuits QuantitySplice Circuits Quantity

Circuit Details MPS Schedule Stock Profile Build Schedule

Both Ends Common Crimp

Common CircuitVersionCode

MPS Scheduled Line Issue dates from DHS

MRP Suggested Cutting Quantity and Date

MRP Suggested Cutting Quantity outside of 5 Day Lead Time

Cut Date03/02/2003

Cut Date10/02/2003

Cut Date17/02/2003


SEWS-E C&C (MRP Status)MRP Status As on >> 10/02/03 <<

Common Product or Product Number : TOYDRLH ( example )

Bundle Qty MRP Suggestions

A Side B Side BECC CCVC 10/02/2003 17/02/2003 24/02/2003 Safety Stock Arrears Current Future 1 Week 1 Week 17/02/2003

#PO P79 0 60 240 240 240 60 0 0 480 300 0 0 0#R1 JAV 0 60 240 240 240 60 0 0 480 300 0 0 0$NE JAT 0 60 240 240 240 60 0 0 480 300 0 0 0$NL JAU 0 60 240 240 240 60 0 0 480 300 0 0 0$QE Q43 0 60 240 240 240 60 0 0 480 300 0 0 0$QT Q17 0 60 480 480 480 60 0 0 960 540 0 0 0$QU Q18 0 60 480 480 480 60 0 0 960 540 0 0 0%Z3 #ZE 0 60 240 240 240 60 0 0 480 300 0 0 0%Z3 &EA 0 60 360 360 360 60 0 0 720 420 0 0 0%Z3 JAW 0 60 240 240 240 60 0 0 480 300 0 0 0%Z3 Z62 0 60 240 240 240 60 0 0 480 300 0 0 0%Z3 ZHU 0 60 240 240 240 60 0 0 480 300 0 0 0*1 *2 0 60 480 480 480 60 0 0 960 540 0 0 0JJJ PM1 0 60 240 240 240 60 0 0 480 300 0 0 0JJJ PM4 0 60 240 240 240 60 0 0 480 300 0 0 0JJJ PMZ 0 60 240 240 240 60 0 0 480 300 0 0 0P64 P80 0 60 240 240 240 60 0 0 480 300 0 0 0P65 P81 0 60 240 240 240 60 0 0 480 300 0 0 0PNK PNM 0 60 240 240 240 60 0 0 480 300 0 0 0PP4 PMW 0 60 240 240 240 60 0 0 480 300 0 0 0R47 R86 0 60 480 480 480 60 0 0 960 540 0 0 0R48 R52 0 60 480 480 480 60 0 0 960 540 0 0 0

0 0 13200 7700 0 0 00 0 4800 2800 0 0 00 0 2880 1740 0 0 00 0 5520 3160 0 0 00 0 13200 7700 0 0 0

868

22

Past Due Suggestions

Total QuantitySingle Circuits QuantitySplice Circuits Quantity

Circuit Details MPS Schedule Stock Profile Build Schedule

Total Sub Circuits Total Circuits

Sub Circuits QuantityGrand Total

Total Single CircuitsTotal Splice Circuits

Both Ends Common Crimp

Common CircuitVersionCode

MPS Scheduled Line Issue dates from DHS

MRP Suggested Cutting Quantity and Date + Emergency 2 qty

MRP Suggested Emergency 1 Quantity added to Current ad-hoc tkts made

Cut Date03/02/2003

Cut Date10/02/2003

Cut Date17/02/2003


SEWS-E C&C (Stock System Leads Flow)

CCBUILD

SCHEDULES

KOMAX

LEADSTORES

SPLICESETS

&SINGLE

SETS

SUB ASSEMBLY

HARNESSASSEMBLY

NETWORK&

NON NETWORK

SINGLESETS

SPLICING&

SPLICE SETS

98% MINIMUM

ACCURRACY

98% MINIMUM

ACCURRACY

MRPCALCULATION


SEWS-E C&C (Data Maintenance)

• SAFETY STOCK MAINTENANCE AT FAMILY LEVEL ( CST PLANNER )

• SLOW MOVING STOCK MONITOR MAINTENANCE ( CST PLANNER )

• CST BUILD SCHEDULE MAINTENANCE 98% ( CST PLANNER )

• STOCK ACCURACY 98% ( LEAD STORES )

• MRP CHECK AND ANALYSIS ( CST PLANNER )

• MEASURES OF PERFORMANCE ( CST PLANNER )

• MACHINE CONSTRAINTS DATA (CST PLANNER )


SEWS-E C&C (Stock Processing)

• BAR CODE TRANSACTIONS

• BOOK IN FROM KOMAX , SINGLE / SPLICE LEADS

• SUB ASSY LEADS DIRECT TO SUB ASSY AREA

• MANUALLY BOOK IN LEADS FROM OTHER FACTORY

• BOOK IN SUB ASSEMBLY LEADS AFTER PROCESSING

• SCANNER DOWNLOAD CONVERTS BUILD SCHEDULES INTO STOCK QTY

• CIRCUIT AVAILABILITY TO CHECK STOCK

• CYCLE COUNTING TO MAINTAIN STOCK ACCURACY ( MIN 98% )

• BOOK OUT PRODUCTS OR CIRCUITS / SINGLE OR SPLICE

• CIRCUIT COMPARISON FUNCTION TO FIND ALTERNATIVE CIRCUITS

• BOOK IN FROM ASSEMBLY AREAS


SEWS-E C&C (Stock Processing)

• PROGRAM THAT CREATES CUTTING SEQUENCE

• PROCESSES “SETS” OF HARNESSES

• DESIGNED FOR DAILY / WEEKLY CUTTING

• SEQUENCE LOGIC BASED ON MINIMUM CHANGEOVERS

• ALLOWS MANUAL OPTIMIZATION TO M/C SEQUENCE

• “ SETS “ TRACKING BY LINE ISSUE DATE

• AUTO CPS FROM DHS SYSTEM

• CREATES COMMON CIRCUIT OPTIONS

• MRP GENERATED CUTTING SCHEDULE• LEAD STOCK VISION

• SAFETY STOCK FUNCTIONALITY

• LEAD AVAILABILITY REPORTS

• SLOW MOVING STOCK MONITOR• LEAD MATCHING FUNCTIONALITY

• BAR CODE SCANNING TRANSACTIONS

• STOCK COST INTERFACE WITH DHS


End Of Slide

Thank You

Business

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