MULTIDISCIPLINARY SENIOR DESIGN

ANDON SYSTEM FOR TPS LAB

PROJECT REVIEW

Trevor Andrews

Holli Monroe

Emily Piccione

William Wright

Project Team Project Description Customer Needs Specifications Bill of Materials Final Design

Mechanical System A Mechanical System B Electrical System

Test Summary and Results User or Operator Instructions/

Manual Service Instructions/ Manual Lessons Learned Questions

AGENDA

Trevor Andrews Industrial & Systems

Engineering

Holli Monroe Mechanical Engineering

Emily Piccione Industrial & Systems

Engineering

William Wright Mechanical Engineering

The project team would like to acknowledge and express appreciation to RIT faculty member Scott Bellinger for all of his help and assistance in executing this project.

PROJECT TEAM

In order to improve quality on the four-station assembly line within the Toyota Production Systems Lab at the Rochester Institute of Technology, two andon systems and a corresponding monitoring system were developed.

One andon system consists of simple electronics controlled by predetermined logic.

The other andon system is purely mechanical in nature.

In order to highlight and record abnormalities, which can later be used to perform root cause analysis and develop preventative countermeasures, a monitoring system was designed alongside the andon systems.

PROJECT DESCRIPTION

CUSTOMER NEEDS

SPECIFICATIONS

BILL OF MATERIALS

Under $3,000 budget!

FINAL DESIGN – MECHANICAL SYSTEM A

FINAL DESIGN – MECHANICAL SYSTEM B

FINAL DESIGN – ELECTRICAL SYSTEM

FINAL DESIGN – ELECTRICAL SYSTEM

TEST SUMMARY AND RESULTS

For more on Test Summary and Results consult EDGE webpage.

System States Test Station #1 Station #2 Station #3 Station #4

Step Green Andon E-stop Green2 Andon3 E-stop4 Green5 Andon6 E-stop7 Green8 Andon9 E-stop10 Global Local Light Tree Audio Red? Reset? Commentsnone 1 0 0 0 0 0 0 0 0 0 0 0 0 ✓ N/A N/A N/A Need to bring VI online.

2 1 0 0 0 0 0 0 0 0 0 0 0 ✓ N/A N/A N/A Need to bring VI online.3 0 0 0 1 0 0 0 0 0 0 0 0 ✓ N/A N/A N/A Need to bring VI online.4 0 0 0 0 0 0 1 0 0 0 0 0 ✓ N/A N/A N/A Need to bring VI online.5 0 0 0 0 0 0 0 0 0 1 0 0 ✓ N/A N/A N/A Need to bring VI online.6 1 0 0 1 0 0 0 0 0 0 0 0 ✓ N/A N/A N/A Need to bring VI online.7 1 0 0 0 0 0 1 0 0 0 0 0 ✓ N/A N/A N/A Need to bring VI online.8 1 0 0 0 0 0 0 0 0 1 0 0 ✓ N/A N/A N/A Need to bring VI online.9 0 0 0 1 0 0 1 0 0 0 0 0 ✓ N/A N/A N/A Need to bring VI online.

10 0 0 0 1 0 0 0 0 0 1 0 0 ✓ N/A N/A N/A Need to bring VI online.11 0 0 0 0 0 0 1 0 0 1 0 0 ✓ N/A N/A N/A Need to bring VI online.12 1 0 0 1 0 0 1 0 0 0 0 0 ✓ N/A N/A N/A Need to bring VI online.13 1 0 0 1 0 0 0 0 0 1 0 0 ✓ N/A N/A N/A Need to bring VI online.14 1 0 0 0 0 0 1 0 0 1 0 0 ✓ N/A N/A N/A Need to bring VI online.15 0 0 1 0 0 1 0 0 1 0 0 ✓ N/A N/A N/A Need to bring VI online.16 1 0 0 1 0 0 1 0 0 1 0 0 ✓ N/A N/A N/A Need to bring VI online.17 0 1 0 0 0 0 0 0 0 0 0 0 ✓ ✓ ✓ Need to bring VI online.18 0 0 0 0 1 0 0 0 0 0 0 0 ✓ ✓ ✓ Need to bring VI online.19 0 0 0 0 0 0 0 1 0 0 0 0 ✓ ✓ ✓ Need to bring VI online.20 0 0 0 0 0 0 0 0 0 0 1 0 ✓ ✓ ✓ Need to bring VI online.21 0 1 0 0 1 0 0 0 0 0 0 0 ✓ ✓ ✓ Need to bring VI online.22 0 1 0 0 0 0 0 1 0 0 0 0 ✓ ✓ ✓ Need to bring VI online.23 0 1 0 0 0 0 0 0 0 0 1 0 ✓ ✓ ✓ Need to bring VI online.24 0 0 0 0 1 0 0 1 0 0 0 0 ✓ ✓ ✓ Need to bring VI online.25 0 0 0 0 1 0 0 0 0 0 1 0 ✓ ✓ ✓ Need to bring VI online.

29 0 1 0 0 0 0 0 1 0 0 1 0 ✓ ✓ ✓ Need to bring VI online.

Expected Behaviors

Onl

y gr

een

light

(s)

Onl

y ye

llow

light

(s)

82 states were tested and their expected behavior was monitored for accuracy• Global: does the global display depict proper states• Local: do the local displays depict proper states• Light Tree: does the light tree illuminate according to button press• Audio: does music play when an andon alert exists• Red: does a yellow andon alert escalate to a red andon alert after X% of TAKT• Reset: does pressing the andon button a second time reset the andon alert

For more on User or Operator Instructions/ Manual consult EDGE webpage.

USER OR OPERATOR INSTRUCTIONS/ MANUALA user or operator instructions/manual was crated to guide team members through the proper use of the various andon systems.

For more on Service Instructions/ Manual consult EDGE webpage.

SERVICE INSTRUCTIONS/ MANUAL

A service instructions/manual was crated to guide team leaders and lab instructors through the proper set-up, modification, and maintenance of various andon systems.

LESSONS LEARNED

Ladder Logic Functions of a PLC How to wire, use longer wires originally

QUESTIONS?