AUDI Belgium, Brussels
The Poka-Yoke system has been installed In the Audi Brussels plant in 2010. The Poka-Yoke server is a virtual server. The system stores all the data in an Oracle database, what later depending on requests can be recalled, and will permit to write reports and prepare statements. The system is fully Ethernet network based. The settings and queries are web based. We receive the car data from the IBM MQ MONA server. The connection between the server and the line controlling PLC is a special Ethernet- Siemens based solution.
Next to our devices installed in the plant is situated our RFID reader what reads the data from a standard MOBY-U RFID tag. From here we forward it to the server, what gives the relevant data to the connected devices.
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).
The TVP has identification functions. The parts which are often confused can be easily identified with their bar code. The bar code of the components -what has to be built in to the incoming car first- has to be scanned. After identification of the correct component, we signal to the operator with a green light that this is the correct component built in. In case the operator scans the wrong component we signal that he needs to change it. In case the operator did not identify the matching component, or he is out of the time limit we stop the line until the error is repaired.
Special devices like the device greasing the panoramic windows receive information from the Server that what is the exact type of the car, and what type of panoramic window has to prepare for the greasing step. Any kind of PLC and PC device can be installed in the system, so it can get online information.