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SUZUKI Assembly Shop
SUZUKI Welding Shop SUZUKI Painting Shop
SUZUKI Assembly Shop Click on the picture to enlarge
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semmi
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SUZUKI Hungary, Esztergom

Assembly shop:
A complete production control system and a  Poka-Yoke system have been installed  in the Suzuki assembly shop in 2003. The production control and the Poka-Yoke server part are done by one server as well. The system stores all the data in the database, what later depending on requests can be recalled, and will permit  to write reports and prepare statements.
All the lines are controlled by one PLC. A Sub-Master PLC is controlling the lines one by one. The Sub-Master PLC is identifying the car on the beginning of the line (RFID basis) and it traces the car all the way long and it controls the devices like Pick-to-light shelves, Screw-driver controllers, special devices, and so on.
The Sub-Master PLC’s are managing and controlling the Andon system as well, what helps the team leaders at the line. If the operator notices an error or he cannot finish his job, then he can call the team leader of the line with the Andon system.
The Pick to Light shelves help the operators to pick the right component. When a car arrives to a workplace, a light above the component glows. This shows if the given component should be picked. The operator needs to acknowledge this otherwise the line will stop.
The torque wrench controllers are helping the operator with the information that how many screws have to be tighten to be built in properly. At every tightening the system counts down one. The tightening can be done with a torque wrench or with a screwdriver (BOSCH EXACT SEC).
Special devices like loaders or the rear window greaser robot receive information from the Sub-Master PLC that what is the exact type of the car, and how much fluid and which kind of fluid has to be filled in, also which type of window needs to be greased by the operator. Any kind of PLC device can be installed in the system, so it can get online information.
 
Painting shop:
A complete production control system and a  Poka-Yoke system have been installed  in the Suzuki painting shop in 2005. The production control and the Poka-Yoke server part is done by one server as well. The system stores all the data in an MS SQL database, what later depending on requests can be recalled, and will permit  to write reports and prepare statements.
In the whole Suzuki Paint Shop we identify the cars with RFID. After identification we redirect the cars to the appropriate lines, where the devices and the operators work according to the received data.
On every lines there is ANDON system installed, what helps the job of the team leaders. If the operator notices an error or he cannot finish his job, then he can call the team leader of the line with the Andon system.
The Pick to Light shelves help the employees to pick the right component. When a car arrives to a workplace, a light above the component glows. This shows if the given component should be picked. The operator needs to acknowledge this otherwise the line will stop.
The special devices like Painting or SGC Robot receive information from the Sub-Master PLC in that area. They receive information like what type is the car, what colour it should be painted to or that the robot needs to work or not.
 
Welding shop:
A complete production control system and data collection have been installed  in the Suzuki welding  shop by Ethernet network in 2006. The whole system is based on the MS SQL. When installing the system it had to be taken into consideration that potential upgrades should be possible. That is why the network is divided into two parts, each of them with two optical rings. The first optical ring network is responsible for production control, displays and special devices, while the second one is responsible fully for the data collecting and the analysing program.
The production control is industrial PC based. The central server collects and sends the data to the PC’s. According to this data the PC’ control the PLC’s on the line. The program operating mode has different types what depends on the production method (one by one, by Production LOT, or by reversed production LOT).
The data collecting is done in two steps. Every timers (welding controlling device) and PLC are connected to the Ethernet network (about 800 nodes). The data collectors in the area (Line Side PC) collect the data from these, and sends it to the central data collecting server (Collection Server). From this collected data the Analysis server creates reports and prepares statements. This is visualized in the shop and in the office on more places on large plasma displays.