5 november 2008 evoluon - eindhoven omro n lcia bram kale european engineering manager. omron omron...

5 november 2008

Evoluon - Eindhoven OMRON

LCIABram KaleEuropean Engineering manager

.OMRON

Omron Europe B.V

5 november 2008

Evoluon - Eindhoven OMRON

OMRON Industrial automation

• Japanese multinational• 35.000 employees• 5.8 Billion in Euro• Industrial automation products

PLC’sPLC’s

Card-ReadersCard-Readers

Human Machine Human Machine InterfaceInterface

Motion Control (OYMC)Motion Control (OYMC)

Vision & ID systemsVision & ID systems

Timers & CountersTimers & Counters SensorsSensors

5 november 2008

Evoluon - Eindhoven OMRON

Engineering

SMT automated production

AssemblyManual productionLCIA assembly

5 november 2008

Evoluon - Eindhoven OMRON

LCIA Assembly

• DescriptionLCIA – Low Cost

Intelligent Automation is a system for effective manual production, where manual stages, simple control systems and clever tools are integrated to a flexible, productive and high quality method of assembly.

5 november 2008

Evoluon - Eindhoven OMRON

5 november 2008

Evoluon - Eindhoven OMRON

LCIA assembly

• Productivity improvement

• Reduction of Quality problems

• Increase production Flexibility

Focus points:

5 november 2008

Evoluon - Eindhoven OMRON

2. Synchronization of Chain of Processes

1. Consequent Elimination of Waste[Muda]

Anchor in theline set up

Drivers of the system

LCIA assembly

-Overproduction-Waiting time-Transportation-Processing-Inventory-Motion-Product defect

5 november 2008

Evoluon - Eindhoven OMRON

LCIA assembly

Balance the strong points of the worker

Flexible

Intelligent

Accurate

Repetitive

with those of the machine

5 november 2008

Evoluon - Eindhoven OMRON

Basics of LCIA assembly

•Flexible number of operators in line•Make many products in one line•Quick change over time•Easy to train operators •Standing style operations

Productivity Quality Flexibility•One-piece flow, fixed # WIP•Standardized labor•Ergonomically sound•everything in a fixed place (5S)•LCIA solutions•Fool-proof (Poka-Yoke) solutions

•Efficient work allocation•Teamwork •Paced to (stable) cycle time•Easy & not disturbing material replenishment from outside•Visual management

Line: CPM1A-V1 Buffer Safety Quality Scale:

Version: 2.2 (2 man) Standard Work Combination Sheet marking marking controlPitch Time: 112 dm - 127 dm 0.5 meter

4)

6) Final Test

5) CSA Test

PS-PCB

Con.opPS

Rear Case

Slid-ers

CPU PCB

Front-case

Perif Cov-

er

Labe

lP.

la.

Bo

ok

Package

1 2 3 4

5

6

710 9 81

1) 3)2) 2.1)

Guid

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7)8)10) 9)11)Complete

Paced to (stable) cycle timeStandardized labor

Fool-proof (Poka-Yoke) solutions

•Flexible number of operators in line

Standing style operations

5 november 2008

Evoluon - Eindhoven OMRON

LCIA effect

Productivity Quality Flexibility

CQM1 PLC assembly line:Cycle time reduction of 250%

5 november 2008

Evoluon - Eindhoven OMRON

LCIA effect

Productivity Quality FlexibilityFrom:•Manual visual check•Avg 63 customer complaints per year•Estimated >1000 defects per year

Wrong colorIntensity

To•Low cost vision system•Zero defect &Inspection time reduction (20 sec)

No illuminationLED allways on

5 november 2008

Evoluon - Eindhoven OMRON

LCIA effect

Productivity Quality Flexibility

35 different product in one line with change over time <30 sec.

5 november 2008

Evoluon - Eindhoven OMRON

Design process

• Line design very early in the product development process• Use Process FMEA to predict possible fault causes• Decide necessary tools based on FMEA level• Detailed Line Design and assembly• Test runs, measure designed cycle times, optimization

5 november 2008

Evoluon - Eindhoven OMRON

• Thank you for your attention