Automotive InTouch HMI, Wonderware System Platform, Operations, Supply Chain Connector

Wonderware MES, Operations and Performance -Car factory MES project in three months

Industry: Automotive

www.valmet-automotive.com

Objectives • Bi-directionaldatatransferbetweenautomationandERP

systems• Electronicdocumentationofproduction• Billofmaterials(BOM)management• Traceabilityofmaterialsandendproducts• Productqualitymanagement

Challenges • Theshortestpossibleimplementationtime• Systemsintegration• Easeofuse

Solutions • WonderwareInTouchHMI• WonderwareSystemPlatform• WonderwareOperations• WonderwareSupplyChainConnector

Results • Modularandeasilymodifiedsystemthatisintegrat-

ed with other systems in the car factory• FlexiblemanagementofproductiondataandBOMs• Webbasedreportinghelpspublishingthechosen

databothinternallyandtointerestedparties

Picture 1 Valmet Automotive, Uusikaupunki plant

Automotive InTouch HMI, Wonderware System Platform, Operations, Supply Chain Connector

Valmet Automotive implemented a MES pro-ject with Wonderware Operations and Perfor-mance suite in summer 2009, covering their Garia Production. With the new solution, exibility of production and change manage-ment could be strenghtened, in response to the challenges presented by the fast change in the market. The whole MES project of the car factory was completed in three months, using the Wonderware Operations and Performance program suite.

ValmetAutomotiveproducesdesignandmanufacturingservicesforthecarindustry.Thefactoryaimsforexibleproduction, in order to start new products in record timeandproducethemexiblyfordemandingcustomersaround the world.

ValmetAutomotivehasrespondedtochangeintheautomotivemarketbyrenewingitsserviceoering.InNovember2008,ValmetAutomotivewonacontractwiththeAmericanFiskerAutomotivetomanufactureanddeveloptheFiskerKarmahybridinFinland.InJanuary2009,anagreementwasreachedwiththeDanishGariaA/Stodesignandproducealuxuryclassgolfcar.InAugust2009,ValmetAutomotiveandNorwegianThinkGlobalASsigneda letter of intent that will make Valmet Automotive apartnerindesigningandmanufacturingtheThinkCityelectriccar.TheproductionofthegolfcarandThinkCitybeganinDecember2009.TherstFiskerKarmaswillbedeliveredintheendof2010.

ValmetAutomotivehasproducedmorethan220.000PorscheBoxsterandPorscheCaymansportscarssince1997;alltogethermorethan360.000convertibleshavebeenmanufactured.

Valmet Automotive serves the internationalautomotiveindustrybyoeringservicesthatcomplyto customers’ wishes and demands. The advancedautomation of the production and the production datamanagementareimportantpartsofValmetAutomotive’s customer service and competitionadvantage.

The production automation system of the plantcontrolstheproductiondepartments(welding,painting,assembly).ItisrmlybundledtothefactorysERPinformationsystemthatcoordinatescustomer orders, materials purchases and production,as well as oers reports for internal use, for customersandforpartnerorganisations.

Valmet Automotive and Wonderware MES

Valmet Automotive has used Wonderware automationprogramsintheirproductionautomationsincethemid-1990’s.Wonderwaremanagementanddatabaseprogramsconnectexiblytoautomationdevicesfromdierentsuppliers,creatinganeasilymanagedandreportableunit.

When Valmet Automotive started co-operation with newcustomersinearly2008,productionmanagementneededupgradingtoanew,moreexibleandtranspa-rentapproach-theanswertothisnewchallengewastoacquireandimplementaMESsolution.

ValmetAutomotivesMESsolutioncomprisesofWon-derwareOperationsandPerformanceMESprograms(SystemPlatform,Operations,SupplyChainConnectorandInTouchsuites).TheadvantagesoftheWonderwaresolution are seen as follows:• EasilyconnectedtoautomationandITsolutionsfrom

dierent manufacturers• Bi-directionaldatatransferbetweentheautomation

andERPsystems• Productiondataacqusitionandpresentation,ready-

madereportingtools• Configurableandfullycompatibleprogrampacka-

geswithgoodbasicfunctionality,easilyenhancedtocomplete the project within schedule

• Broadprogramsuiteallowsenhancementofoperati-on at a later date

Picture2.ValmetAutomotive,Uusikaupunkiplant

WonderwareMESsolutionforValmetAutomotiveproduc-tionwascompletedinthreemonthsinsummer2009.The fast project development and implementation of theMESsolutionassistedValmetAutomotiveinitseortstoadjustproductionprocessestothechangedmarketsandcustomer needs.

Automotive InTouch HMI, Wonderware System Platform, Operations, Supply Chain Connector

Wonderware MES connects Microsoft NavisionERP and line automation

TheclientsMicrosoftNavisionbasedERPsystemhandlescustomerorders.SystemsbyV-ALogisticstake care of materials purchases, deliveries andinvoicing.ProductionmanagementisdonebyMES.

WonderwareOperationsandPerformanceMESconnectstoproductionmanagementsystemsandcontrolsolutionsof the dierent production lines. The system receives pro-ductionordersfromtheERPsystemaccordingtocustomerdemand, divides the orders to components for purcha-se and production and, processes each customer order throughthewholemanufacturingprocess.TheMESsystemupdatesthestatusofeachorderbacktotheERPsystem,providingrealtimeordertracking.WonderwareOpera-tionsandPerformancealsohandlesmaterialtrackingforproductionandprintsoutlabelsfordispatch.

LineoperationsworkstationsoneachproductionlinesuperviseandreporttheoperationofeachsubprocesswithWonderwareInTouchHMI/SCADA(commencing,qualitycontrol,assemblyanddispatch.)

Wonderware Operations and Performance MES brings clear advantages to the production environment.

With Wonderware Operations and Performance, Val-metAutomotivehasgotnumerousnewfunctionsatitsdisposal, that enhance production:• WonderwareOperationsandPerformancemanages

electriccommunicationwithbothERPandproductionsystems, and automation components from dierent manufacturers,integratingthesystemsintooneeasilyadministered unit.

• MESprovidesforcentralizedBOMmanagementforexibleproduction-whenproductsandmodelschange,alterationscanbemadepromptly.

• Tracingofmaterialsandendproducts.• Electronic,automaticandmanualentries(assembly

points,qualityinspections,etc.)• Browserbasedreportingthatallowsappropriatedata

tobepublishedtothosewhoneedthem.• Thesystemiseasilymodifiedwhennewrequirements

arise.

Picture3ValmetAutomotive(Uusikaupunki).MESsolutionconfiguration

ERP

MES-SRV-1 MES-WS-S1

MES-WS-O1 MES-WS-O2 MES-WS-O3 MES-WS-O4

Logistic systemsCar orders

System i nterfacesProduction ordersBOMWorkschedule

EthernetTCP/IP100Mb/s

ReportsProduction management serverWindowsServer2003MSSQLServer2005WWSystemPlatform3.1WWOperations3.5WW Supply Chain Connector

Production planningWindowsXPSP2WebClient

WindowsXPSP2WWInTouch10.1

Oce workstations

Commencing Quality control Assembly Dispatch

Component ordersDispatchInvoicing

SQL

SQLSQL

This document was realized thanks to the support of:Valmet Automotive.

Automotive InTouch HMI, Wonderware System Platform, Operations, Supply Chain Connector

Logistics Mgr

Master DataManagement

Plant Mgr

Mfg Exec /Dispatching

ProductionPlanner

InventoryMgt

Operations Mgr

Quality Mgr

SPC / QM

Production Mgr

SpecificationManagement

OEE / KPIPerf. Analysis

QA Manager

Traceability

Line Mgr

MachineSetup

Lab Tech

FormulaManagement

Operator

Visualize / HMI

Engineer

Diagnostics

Maintenance

Alarm Mgt / Notify

Operations ManagementProduction Performance & QualityProduction Execution

Process Analysis

Multiple Plant Sites

Evolving Plant Model for

ManufacturingOperations

ProductionModel

Business Processes

LogisticsManufacturing

OperationsPlanning

Wonderware MES-software

Operations Improved inventory velocity

Reduced production order lead time

Reduced time-to-volume for new product introductions

Improved compliance and governance

Improved predictability of order fulfillment

Wonderware System Platform Achieve your business goals without abandoning prior investments

Reduce the effort and costs in building standardized applications for MES and EMI

Improve production processes

IT platform that offers complete scalability

Open and distributed environment for integration capabilities

Performance Reduced capital expenditures

Improved asset utilization

Increases the capacity of your existing assets

Leverages best practices

Quality Minimize costly scrap and rework

Reduce the safety margin

Perform corrective and preventive actions

Relate production and process quality

Batch optimal utilization of shared equipment and raw materials

Manage complex batch processes more effectively

Reduce lifecycle engineering efforts using simplified control code according to S88 industry standards

Package solutions from the market leader

Mobile Workforce & Decision Support System – IntelaTrac Accelerates and sustains operational process improvements

A key component of an effective Operations Management System

Inspection and regulatory procedures, assign, schedule and execute rounds and report back

Modules to deliver best practices and collect data to ensure goals

Enterprise Integration Improved production throughput and on-time delivery

Increased visibility and responsiveness

Dispatch information and local production work orders

Adopt industry standards like ISA-95

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