TETRA PROYECTOS has successfully concluded the implementation of the new Management System of Production (MES) in one of the main manufacturers in the community of Valencia and direct supplier of FORD ALMUSSAFES.
The production plant has 2 assembly lines for the seats (front and rear) with a total of 97 operation stations, that are each configurable and with which you get to choose what type of work you want it to perform.
With the previous system, the operator had to read, by means of a Barcode Scanner, the “Palette” of production’s label, this information was sent to the previous system of Production through the PLC and it showed the operator the work that had to be done for these types of seat. Any type of change in the assembly operation meant a system reprogramming with its consequent Commissioning and subsequent adjustments.
The Llave en Mano Project includes the installation of a RFID system, which automatically identifies the “Palette” of Production in each one of the stations and that then sends the information needed without the need of an intervention from the operator, freeing him from any unproductive tasks.
With the new program, it is possible to configure each one of the stations without the need for reprogramming the MES application, which allows balancing the line based on the production without having to wait for the production to stop to apply the changes.
Moreover, the cycle time control system has also been modified and it can detect “Bottlenecks” in the production stations operations but also failures in the supply of materials, etc. With those new modifications, the system is capable to identify the production stations that exceed the most their preset time cycle. A “TOP FIVE” list is then created to show the most problematical stations, and it is sent immediately via E-mail to the ones responsible for the production. All of this takes place without the need of a third- party intervention.
The modifications also includes an automatic exportation system , every shift of production, of the EXCEL format DATA that can be analyzed at any time by those responsible who then have the opportunity to have a look at the production’s evolution and at its problems.
A team with employees from Valencia, Barcelona and Austria has been composed for the realization of this Project.
The Project launching has been carried out in a record time during the 3 weeks of production stoppage.
