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Challenges)in)the)automa/on)of))visual)harmony)control)in)produc/on)lines)
Juanfra'Forés'Business)Development)Manager)EINES'Quality'Engineering'&'Vision'Systems
Extensive)experience)in)the)automa/on)of)quality)control)systems)
who)and)where)Ford Valencia, Spain
Opel Zaragoza, Spain
Mazda Valencia, Spain
Ford Köln, Germany
Ford Genk, Belgium
Ford Saarlouis, Germany
Visteon Valencia, Spain
Ford Southampton, UK
GM Holden Adelaide, Australia
SAAB Trollhättan, Sweden
Ford Kentucky, USA
Ford Hermosillo, Mexico
NISSAN Smyrna, USA
GM Arlington, USA
Mitsubishi Illinois, USA
Dynamit Nobel Valencia, Spain
HYUNDAI Montgomery, USA
Land Rover Solihull, UK
Faurecia Ourense, Spain
Ford Melbourne, Australia
PSA Peugeot Citroën Vigo, Spain
Ford St Thomas, Canada
Gamesa Valencia, Spain
Volvo Gent, Belgium
Volvo Torslanda, Sweden
GM Rüsselsheim, Germany
Gestamp Cerveira, Portugal
K.S.C Ahwaz, Iran
SAS Automotive Valencia, Spain
Renault Samsung Motors Busan, Korea
Mercedes Benz Vitoria, Spain
VIZA Pilsen, Czech Republic
Casting ROS Utrillas, Spain
Faurecia Scheuerfeld, Germany
Standard Profil Düzce, Turkey
Ford Otosan Kocaeli, Turkey
Ford Craiova, Romania
Voith Coventry, UK
HONDA Swindon, UK
GM Oshawa, Canada
Johnson Controls Valencia, Spain
Ford St. Petersburg, Russia
Perceiving process issues as soon as possible
! better colour-matching to hang-on parts ! increasing customer satisfaction ! being better than competitors
4)
Main)objec/ves)Color Quality Measured/Controlled
100% production
Basic)requirements)(PaintCShop))
• 100%)produc/on)inspected)• Minimum)of)4)points)on)each)side))
Rear fender
Front fender
doors 5)
Typical)requirements)(PaintCShop))
• 100%)produc/on)inspected)• Preferable)all)panels)
Rear fender
Front fender
doors 6)
Hood
Roof
Tailgate
Basic)requirements)(FinalCAssembly))
• 100%)produc/on)inspected)• Minimum)of)4+)points)on)each)side))
Rear fender Front Fender 7)
Front Bumper
Rear Bumper
Typical)requirements)(FinalCAssembly))
• 100%)produc/on)inspected)• ALL)panels)including:)doors,)fender,)molding)and)door)handles,)fuel)flap)cover,)mirrors,)spoiler.)
Rear fender Front Fender 8)
Front Bumper
Rear Bumper Fuel Flap Cover
Spoiler Mirrors
Door handles
• HMI)!)Measurement)results)should)be)presented)to)the)operators)in)an)easy)way)
• Easy)version)of)measurement)results)shall)be)transferred)to)the)Plant)Quality)System)(green,)yellow,)red))
• Measurement)values)shall)be)stored)for)process–engineering)separately))
9)
System)requirements)
Technical)challenges)
• Produc/on)complexity)(models,)sizes,)shapes,)colors))• Ambient)Light)influence))• Posi/oning)Influence)• Temperature)influence)• Mul/ple)controls)(thickness,)orange)peel,)color)harmony))• Self)–)Test,)verifica/on)&)calibra/on)• Automa/c)Una`ended)system)• Data)collec/on)and)reports))• Immediate)feedback)to)process)&)quality)engineering)• Produc/on)flow)and)traceability) 10)
11)
66--PANELPANEL
Originated: September 9, 2011, Updated: September 12, 2011Page 17 of 26Corporate 6-PANEL Template version 3.3.ppt
© 2002-2005, Ford Motor Company ANALYZE y=f(x)ANALYZE y=f(x)DDD MMM AAA III CCC RRR
30 measurements of each measuring point without robot movement i30 measurements of each measuring point without robot movement in n combination with alternating on and off ambient lightcombination with alternating on and off ambient light
Measurement Setup for Step 4Measurement Setup for Step 4
12
1
2
6CSigma)studies)
• Step)1)C)Reference)values)(Gage)R&R)))• Step)2)C)Comparison)data)(Master)panels)))• Step)3)C)Light)influence)(Master)panels)))• Step)4)C)Comparison)data)(Produc/on)Parts)))• Step)5)C)Light)influence)(Produc/on)Parts)))• Step)6)C)Gage)R&R)data))• Step)7)C)Temperature)influence)(by)degrees)))• Step)8)C)Temperature)influence)(by)/me)of)day)))
12)
13)
66--PANELPANEL
Originated: September 9, 2011, Updated: September 12, 2011Page 3 of 26Corporate 6-PANEL Template version 3.3.ppt
© 2002-2005, Ford Motor Company MEASURE CTQ (y) CAPABILITYMEASURE CTQ (y) CAPABILITYDDD MMM AAA III CCC RRR
Process ElementsElement OK AInvestigating BElement Not Capable CElement Removed D
MSA & Process Capability:9 Engineering Test Requirement
test name spec9 Gage R&R: see below. For more
information, please refer to BB-project #56367 (by H.P. Hagedorn)
Cause & Effect Diagram w/ Ranking:
CONTAINMENT (state reasoning if not required): Process Owner Date Before Data After DataState action name mm/dd/yy X.XX Cpk X.XX Cpk• details• details
Gage R&Rs done by H.P. Hagedorn, BB-project #56367
nt variationsmeasuremecolour
Environment Methods
Material
Machines
Personnel
measurement spot
dev ice orientation
measuring angle
dev icesmissing calibration of
adjustmentsincorrect machine
manual dev ices
automatic dev ices
surface conditions
colour tone
offline measurements
inline measurements
dirt on surface
temperature
ambient light
Cause-and-Effect Diagram for colour measurements
14)
15)
16)
Preliminary)conclusions)• BYKCmac)ROBOTIC)Sensor)is)capable)• Project)is)feasible,)it)can)be)installed)with)no)major)changes)in)current)produc/on)lines)(paint)shop)and)final)assembly))
• 3D)robot)guidance)required)• Cycle)/me)is)cri/cal)(~)10)sec.)per)point,)including)movements))
• Es/mated)number)of)robots/devices:)2)(one)per)side))
17)
Process)alterna/ves)
• A))100%)produc/on,)stop&go)• B))loop)for)measuring)only)when)cell)available)• C))offCline)measurement,)“onCdemand”)
18)
Other)considera/ons)• Offline'Cell'for)quality)check)
– More)control)points)can)be)added)– One)robot)+)rotatory)table)!)cost)reduc/on)– Addi/onal)quality)controls)can)be)performed:)i.e.)Thickness,)Orange)Peel)measurement))
– Vehicles)can)be)taken)out)automa/cally)based)on)color)mix/sequence)
19)
Main)System)Components)– Robots&(2)&on&7th&axis&or&Long&arm)
)– Color&Measurement&Device&(2)&
)– EINES&3D&Guidance&System&(Vision&System)&
)– Conveyor&Table&with&clamping&on&the&skids)
– Safety&Fences&and&safety&devices&
– Control&System&• Flow)control)system)• QLS)repor/ng)• Sta/s/cal)Report)capabili/es)• Warning)and)Trends)Analysis)
20)
EINES)3D)Guidance)• Accurate)sensor)posi/on)
reducing)posi/oning)cycle)/me)
• Points)to)inspect)are)precisely)located)
21)
EINES)3D)Guidance)
22)
Video)))
BYKCmac)ROBOTIC)
23)
Video)))
• 100%)produc/on)colour)verifica/on,)on)all)parts,)on)cars)on)wheels)in)a)moving)line)at)a)high)speed)
Rear fender Front Fender 24)
Front Bumper
Rear Bumper Fuel Flap Cover
Spoiler Mirrors
Door handles
Future)Challenges)
Future)Challenges)
25)Video)))
Avenida Henry Ford, 19 – mail box 79 46440 Almussafes (Valencia – Spain)
Phone: +34 96 179 72 91 Fax: +34 96 179 78 02
www.eines.com [email protected]
Thanks for your attention !