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Automotive InTouch HMI, Wonderware System Platform, Operations, Supply Chain Connector
Wonderware MES, Operations and Performance -Car factory MES project in three months
Industry: Automotive
www.valmet-automotive.com
Objectives • Bi-directionaldatatransferbetweenautomationandERP
systems• Electronicdocumentationofproduction• Billofmaterials(BOM)management• Traceabilityofmaterialsandendproducts• Productqualitymanagement
Challenges • Theshortestpossibleimplementationtime• Systemsintegration• Easeofuse
Solutions • WonderwareInTouchHMI• WonderwareSystemPlatform• WonderwareOperations• WonderwareSupplyChainConnector
Results • Modularandeasilymodifiedsystemthatisintegrat-
ed with other systems in the car factory• FlexiblemanagementofproductiondataandBOMs• Webbasedreportinghelpspublishingthechosen
databothinternallyandtointerestedparties
Picture 1 Valmet Automotive, Uusikaupunki plant
Automotive InTouch HMI, Wonderware System Platform, Operations, Supply Chain Connector
Valmet Automotive implemented a MES pro-ject with Wonderware Operations and Perfor-mance suite in summer 2009, covering their Garia Production. With the new solution, exibility of production and change manage-ment could be strenghtened, in response to the challenges presented by the fast change in the market. The whole MES project of the car factory was completed in three months, using the Wonderware Operations and Performance program suite.
ValmetAutomotiveproducesdesignandmanufacturingservicesforthecarindustry.Thefactoryaimsforexibleproduction, in order to start new products in record timeandproducethemexiblyfordemandingcustomersaround the world.
ValmetAutomotivehasrespondedtochangeintheautomotivemarketbyrenewingitsserviceoering.InNovember2008,ValmetAutomotivewonacontractwiththeAmericanFiskerAutomotivetomanufactureanddeveloptheFiskerKarmahybridinFinland.InJanuary2009,anagreementwasreachedwiththeDanishGariaA/Stodesignandproducealuxuryclassgolfcar.InAugust2009,ValmetAutomotiveandNorwegianThinkGlobalASsigneda letter of intent that will make Valmet Automotive apartnerindesigningandmanufacturingtheThinkCityelectriccar.TheproductionofthegolfcarandThinkCitybeganinDecember2009.TherstFiskerKarmaswillbedeliveredintheendof2010.
ValmetAutomotivehasproducedmorethan220.000PorscheBoxsterandPorscheCaymansportscarssince1997;alltogethermorethan360.000convertibleshavebeenmanufactured.
Valmet Automotive serves the internationalautomotiveindustrybyoeringservicesthatcomplyto customers’ wishes and demands. The advancedautomation of the production and the production datamanagementareimportantpartsofValmetAutomotive’s customer service and competitionadvantage.
The production automation system of the plantcontrolstheproductiondepartments(welding,painting,assembly).ItisrmlybundledtothefactorysERPinformationsystemthatcoordinatescustomer orders, materials purchases and production,as well as oers reports for internal use, for customersandforpartnerorganisations.
Valmet Automotive and Wonderware MES
Valmet Automotive has used Wonderware automationprogramsintheirproductionautomationsincethemid-1990’s.Wonderwaremanagementanddatabaseprogramsconnectexiblytoautomationdevicesfromdierentsuppliers,creatinganeasilymanagedandreportableunit.
When Valmet Automotive started co-operation with newcustomersinearly2008,productionmanagementneededupgradingtoanew,moreexibleandtranspa-rentapproach-theanswertothisnewchallengewastoacquireandimplementaMESsolution.
ValmetAutomotivesMESsolutioncomprisesofWon-derwareOperationsandPerformanceMESprograms(SystemPlatform,Operations,SupplyChainConnectorandInTouchsuites).TheadvantagesoftheWonderwaresolution are seen as follows:• EasilyconnectedtoautomationandITsolutionsfrom
dierent manufacturers• Bi-directionaldatatransferbetweentheautomation
andERPsystems• Productiondataacqusitionandpresentation,ready-
madereportingtools• Configurableandfullycompatibleprogrampacka-
geswithgoodbasicfunctionality,easilyenhancedtocomplete the project within schedule
• Broadprogramsuiteallowsenhancementofoperati-on at a later date
Picture2.ValmetAutomotive,Uusikaupunkiplant
WonderwareMESsolutionforValmetAutomotiveproduc-tionwascompletedinthreemonthsinsummer2009.The fast project development and implementation of theMESsolutionassistedValmetAutomotiveinitseortstoadjustproductionprocessestothechangedmarketsandcustomer needs.
Automotive InTouch HMI, Wonderware System Platform, Operations, Supply Chain Connector
Wonderware MES connects Microsoft NavisionERP and line automation
TheclientsMicrosoftNavisionbasedERPsystemhandlescustomerorders.SystemsbyV-ALogisticstake care of materials purchases, deliveries andinvoicing.ProductionmanagementisdonebyMES.
WonderwareOperationsandPerformanceMESconnectstoproductionmanagementsystemsandcontrolsolutionsof the dierent production lines. The system receives pro-ductionordersfromtheERPsystemaccordingtocustomerdemand, divides the orders to components for purcha-se and production and, processes each customer order throughthewholemanufacturingprocess.TheMESsystemupdatesthestatusofeachorderbacktotheERPsystem,providingrealtimeordertracking.WonderwareOpera-tionsandPerformancealsohandlesmaterialtrackingforproductionandprintsoutlabelsfordispatch.
LineoperationsworkstationsoneachproductionlinesuperviseandreporttheoperationofeachsubprocesswithWonderwareInTouchHMI/SCADA(commencing,qualitycontrol,assemblyanddispatch.)
Wonderware Operations and Performance MES brings clear advantages to the production environment.
With Wonderware Operations and Performance, Val-metAutomotivehasgotnumerousnewfunctionsatitsdisposal, that enhance production:• WonderwareOperationsandPerformancemanages
electriccommunicationwithbothERPandproductionsystems, and automation components from dierent manufacturers,integratingthesystemsintooneeasilyadministered unit.
• MESprovidesforcentralizedBOMmanagementforexibleproduction-whenproductsandmodelschange,alterationscanbemadepromptly.
• Tracingofmaterialsandendproducts.• Electronic,automaticandmanualentries(assembly
points,qualityinspections,etc.)• Browserbasedreportingthatallowsappropriatedata
tobepublishedtothosewhoneedthem.• Thesystemiseasilymodifiedwhennewrequirements
arise.
Picture3ValmetAutomotive(Uusikaupunki).MESsolutionconfiguration
ERP
MES-SRV-1 MES-WS-S1
MES-WS-O1 MES-WS-O2 MES-WS-O3 MES-WS-O4
Logistic systemsCar orders
System i nterfacesProduction ordersBOMWorkschedule
EthernetTCP/IP100Mb/s
ReportsProduction management serverWindowsServer2003MSSQLServer2005WWSystemPlatform3.1WWOperations3.5WW Supply Chain Connector
Production planningWindowsXPSP2WebClient
WindowsXPSP2WWInTouch10.1
Oce workstations
Commencing Quality control Assembly Dispatch
Component ordersDispatchInvoicing
SQL
SQLSQL
This document was realized thanks to the support of:Valmet Automotive.
Automotive InTouch HMI, Wonderware System Platform, Operations, Supply Chain Connector
Logistics Mgr
Master DataManagement
Plant Mgr
Mfg Exec /Dispatching
ProductionPlanner
InventoryMgt
Operations Mgr
Quality Mgr
SPC / QM
Production Mgr
SpecificationManagement
OEE / KPIPerf. Analysis
QA Manager
Traceability
Line Mgr
MachineSetup
Lab Tech
FormulaManagement
Operator
Visualize / HMI
Engineer
Diagnostics
Maintenance
Alarm Mgt / Notify
Operations ManagementProduction Performance & QualityProduction Execution
Process Analysis
Multiple Plant Sites
Evolving Plant Model for
ManufacturingOperations
ProductionModel
Business Processes
LogisticsManufacturing
OperationsPlanning
Wonderware MES-software
Operations Improved inventory velocity
Reduced production order lead time
Reduced time-to-volume for new product introductions
Improved compliance and governance
Improved predictability of order fulfillment
Wonderware System Platform Achieve your business goals without abandoning prior investments
Reduce the effort and costs in building standardized applications for MES and EMI
Improve production processes
IT platform that offers complete scalability
Open and distributed environment for integration capabilities
Performance Reduced capital expenditures
Improved asset utilization
Increases the capacity of your existing assets
Leverages best practices
Quality Minimize costly scrap and rework
Reduce the safety margin
Perform corrective and preventive actions
Relate production and process quality
Batch optimal utilization of shared equipment and raw materials
Manage complex batch processes more effectively
Reduce lifecycle engineering efforts using simplified control code according to S88 industry standards
Package solutions from the market leader
Mobile Workforce & Decision Support System – IntelaTrac Accelerates and sustains operational process improvements
A key component of an effective Operations Management System
Inspection and regulatory procedures, assign, schedule and execute rounds and report back
Modules to deliver best practices and collect data to ensure goals
Enterprise Integration Improved production throughput and on-time delivery
Increased visibility and responsiveness
Dispatch information and local production work orders
Adopt industry standards like ISA-95
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Moscowtel. +7 495 641 [email protected]
Кievtel. +38 044 495 33 [email protected]
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Мinsktel. +375 17 200 [email protected]
Tallinntel. +372 668 [email protected]
Samaratel. +7 846 273 95 [email protected]
www.wonderware.fiFinland & Baltic
WW_valmet automotive_eng_4p_0710