Retos en el control de la armonía visual en línea de producción.pptx

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
Ford St Thomas, Canada
Opel Zaragoza, Spain
Gamesa Valencia, Spain
Mazda Valencia, Spain
Volvo Gent, Belgium
Ford Köln, Germany
Volvo Torslanda, Sweden
Ford Genk, Belgium
GM Rüsselsheim, Germany
Ford Saarlouis, Germany
Gestamp Cerveira, Portugal
Visteon Valencia, Spain
K.S.C Ahwaz, Iran
Ford Southampton, UK
SAS Automotive Valencia, Spain
GM Holden Adelaide, Australia
Renault Samsung Motors Busan, Korea
SAAB Trollhättan, Sweden
Mercedes Benz Vitoria, Spain
Ford Kentucky, USA
VIZA Pilsen, Czech Republic
Ford Hermosillo, Mexico
Casting ROS Utrillas, Spain
NISSAN Smyrna, USA
Faurecia Scheuerfeld, Germany
GM Arlington, USA
Standard Profil Düzce, Turkey
Mitsubishi Illinois, USA
Ford Otosan Kocaeli, Turkey
Dynamit Nobel Valencia, Spain
Ford Craiova, Romania
HYUNDAI Montgomery, USA
Voith Coventry, UK
Land Rover Solihull, UK
HONDA Swindon, UK
Faurecia Ourense, Spain
GM Oshawa, Canada
Ford Melbourne, Australia
Johnson Controls Valencia, Spain
PSA Peugeot Citroën Vigo, Spain
Ford St. Petersburg, Russia
Main)objec/ves)
Color Quality Measured/Controlled
100% production
Perceiving process issues as soon as possible
! better colour-matching to hang-on parts
! increasing customer satisfaction
! being better than competitors
4)
Basic)requirements)
(PaintCShop))
•  100%)produc/on)inspected)
•  Minimum)of)4)points)on)each)side))
Front fender
Rear fender
doors
5)
Typical)requirements)
(PaintCShop))
•  100%)produc/on)inspected)
•  Preferable)all)panels)
Roof
Tailgate
Hood
Front fender
Rear fender
doors
6)
Basic)requirements)
(FinalCAssembly))
•  100%)produc/on)inspected)
•  Minimum)of)4+)points)on)each)side))
Front Bumper
Rear Bumper
Front Fender
Rear fender
7)
Typical)requirements)
(FinalCAssembly))
•  100%)produc/on)inspected)
•  ALL)panels)including:)doors,)fender,)molding)
and)door)handles,)fuel)flap)cover,)mirrors,)
spoiler.)
Mirrors
Front Bumper
Spoiler
Fuel Flap Cover
Rear Bumper
Front Fender
Rear fender
Door handles
8)
System)requirements)
• 
• 
• 
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)
Technical)challenges)
• 
• 
• 
• 
• 
• 
• 
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• 
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)
10)
Produc/on)flow)and)traceability)
6-PANEL
D
D
M
M
A
A
II
C
C
R
R
ANALYZE y=f(x)
© 2002-2005, Ford Motor Company
Measurement Setup for Step 4
1
1
2
2
30 measurements of each measuring point without robot movement in
combination with alternating on and off ambient light
11)
Corporate 6-PANEL Template version 3.3.ppt
Page 17 of 26
Originated: September 9, 2011, Updated: September 12, 2011
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)
6-PANEL
D
D
M
M
A
A
II
C
C
R
R
MEASURE CTQ (y) CAPABILITY
© 2002-2005, Ford Motor Company
Cause & Effect Diagram w/ Ranking:
MSA & Process Capability:
Engineering Test
Requirement
test name
spec
Gage R&R: see below. For more
information, please refer to BB-project
#56367 (by H.P. Hagedorn)
Cause-and-Effect Diagram for colour measurements
Material
Personnel
colour tone
dev ice orientation
surface conditions
measurement spot
measuring angle
colour
measureme
nt v ariations
dirt on surface
offline measurements
temperature
inline measurements
missing calibration of
dev ices
incorrect machine
adjustments
manual dev ices
ambient light
automatic dev ices
Env ironment
Methods
Machines
Gage R&Rs done by H.P. Hagedorn, BB-project #56367
Process Elements
Element OK
Investigating
Element Not Capable
Element Removed
A
B
C
D
CONTAINMENT (state reasoning if not required):
State action
• details
• details
Corporate 6-PANEL Template version 3.3.ppt
Process Owner
name
Page 3 of 26
Date
mm/dd/yy
Before Data After Data
X.XX Cpk
X.XX Cpk
Originated: September 9, 2011, Updated: September 12, 2011
13)
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&
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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)
Video)))
22)
BYKCmac)ROBOTIC)
Video)))
23)
Future)Challenges)
•  100%)produc/on)colour)verifica/on,)on)all)
parts,)on)cars)on)wheels)in)a)moving)line)at)a)
high)speed)
Mirrors
Front Bumper
Spoiler
Fuel Flap Cover
Rear Bumper
Front Fender
Rear fender
Door handles
24)
Future)Challenges)
Video)))
25)
Thanks for your attention !
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]