Manufacturing Industry's Stories

MES Implementation - ATS Global's solutions for CARLSBERG

carlsberg


Results:

  • Sales increase by 1.5% due to improved demand response
  • The increase in gross margin of 1.2% on instant and accurate data at the most profitable type of packaging
  • The decrease of downtime from 28 to 13% on all lines
  • The decrease of loss from 1.6 to 0.72% on material for cans
  • 15% efficiency improvement in bottling line
Integrating QMS into Robotic Welding and Painting Process in a Leading Car Manufacturer with ATS Global's solutions

Cars manufacturing


Purpose

  • Perfect robotic welding and painting process
  • Automated self-correction manufacturing and quality process
  • High quality assembly weld with no defects

Project Scope

  • Automated validation for the quality of welding and painting processes
  • Enable manufacturing traceability for each component and system
  • Create a centralized repository for attribute and dimensional data

Solution Approach

  • Capture all the data generated, no matter the type or source
  • Comprehensive analysis of existing equipment and QMS, producing actionable reports
  • Used ATS ADOS – Smart Manufacturing & Industry 4.0 Suite
  • Design to roll-out ownership of integrated robotic manufacturing

Results

  • Streamlining data to a central data location
  • 2% improvement in overal quality of robotic operations
  • Enable the robotic stations for Smart Digital Transformation
  • 10% Reduction in scrap rate due end-to-end traceability

Systems, Tools & Services Expertise

  • ATS ADOS
  • ATS BUS
  • ATS Inspect
  • ATS CM4D
  • 24/7 Support Services
Digital Blueprint Consultancy for a major OEM in Indonesia - ATS Global's solutions

shoes


Purpose

  • To create digital roadmap for customer
  • Define a step by step approach to reach digitalization

Project Scope

  • Map out new processes for digitalization
  • Create digital blueprint for the four manufacturing pillars
  • Identify digital roadmap for step-by-step implementation

Solution Approach

  • Carry out process mapping based on lean six-sigma approach
  • Carry out FMEA to identify potential exception under digitalization in focus
  • Drill down to detail process map to create digitalization input/output for processes
  • Collate requirements to form Digital Development Map and identify projects to achieve them
  • Study the impacts of projects to calculate ROI for justification

Results

  • Clear customer understanding of the virtual representation of their physical processes
  • Ability to prioritize digital development incentives based on potential ROI
  • Create digital culture among core teams involved

Systems, Tools & Services Expertise

  • Lean Six Sigma
  • Smart Industry Readiness Index
Connectivity solutions of HMS Networks for an Australian F&B company - Dairyworks

Dairyworks


Dairyworks source high quality, bulk cheese and butter from local South Island suppliers and package it into consumer products for supermarkets, convenience stores and other retail outlets throughout New Zealand and Australia.

Dairyworks acquire the weight data for reports in real time from a numbers of checkweighers in throughout the factory. Some applications required local PLCs to know product weights for process indication and control. Dairyworks use the Modicon M340 PLC for automation and data control.

This unit is, a powerful and versatile PLC however did not have native support for the ASCII protocol over Ethernet TCP/IP.

Dairyworks solution was to use an eWON 500 to get weight data from all of the checkweighers over the Ethernet TCP/IP connection. We used the eWon script to control/report status of data connections, receive and reformat weight data, tag and store in eWON memory.

The PLC, using Modbus TCP, reads and writes to the eWON memory to get the data it needs and control and test data connections.

The solution is simple, rather inexpensive and has proved reliable. It allows data to be shared on PLCs and HMIs allowing the operators live access to meaningful graphically presented production data.
eWON

Quality Assurance for TOYOTA - ATS Inspect solutions

ats-inspect-toyota-case-study-3-728


The Toyota Quality Division involves vehicle inspection cells, including drum test, wheel alignment, shower and Customer Satisfaction. Toyota’s objectives were to record and report every single defect, in real time, and alert Quality Managers when serious issues arise by
email and SMS.

The ATS Inspect system works as follows. When a vehicle enters the inspection cell, the operator scans the barcode VIN (Vehicle Identifier Number). This vehicle then appears on the system. The Quality operator inspects the vehicle and records any defects found in ATS Inspect using a touch screen.

Any vehicle with defects that cannot be repaired in the Inspection Station is moved to the Hanedashi area (repair area). When the vehicle enters the repair cell, an operator scans the barcode VIN again. ATS Inspect then displays a list of all defects recorded for that vehicle. When rectified, the operator uses ATS Inspect to record that the defects have been repaired.

Real Time Reporting:

A key benefit of ATS Inspect is its ability to feedback information to operators and management alike in real time. The ATS Inspect database structure allows for reporting in any form required. This means that management can review the defect trends and prioritize resources accordingly while the operators can drill-down into the information to see exactly where problems are occurring.

Using ATS Inspect, Toyota has achieved the following:

  • A continuing reduction in the number of average defects per month from ± 20.000 to ± 5.000, and dropping
  • Removed all paper in the Quality Control Division 
  • Reduced the number of resources involved with quality data gathering and reporting (retrained and moved in organisation) 
  • Real time feedback on issues