Assembly Automation Industry 4.0 Success Stories
Bulb Assembly Automation Line
First Time in Turkey Indigenous Assembly Automation
Simatic TIA Portal S7/1500 PLC Bulb Automation line, which is one of the most advanced technology and highest capacity lines in the world, was installed locally in the Makel factory 2017.
Aging, Testing and Packaging machines from China were revised and integrated into German automation technology, up to the complete package consisting of 42 stations consisting of 3 machines. In the aging test machine, 12,000 lamp holders whose XYZ axes did not match each other were revised again by designing a new fixture in a 5-day working day, and disassembly and assembly were carried out. Through the fixture, the XY axes came into precision tolerances. I had support apparatus made at the Aging inlets and outlets for effective vacuuming of the robot's grippers on the Z axis. This prevented deformations of the bulbs that the KUKA robot vacuum gripper in the Z axis + - direction was forcefully seated and the disassembly vacuum force at the outlet of the other robot at the exit were prevented.
The Chinese claimed that the aging test machine could not be integrated into the robot. In addition, I dismantled the Chinese electric motor driven reducers and replaced them with an electric motor reducer with more sensitive brakes. I took it under control with sensors for the correct stop/stop positioning of the reducer so that the robot would not make a positioning error.
I disassembled and disabled the central control unit of the Chinese aging machine. I connected the entire control, including the robot, to the Siemens S7-1500 PLC controller of the Led Bulb Automation machine. Even the Chinese found it impossible to integrate their aging test machines into German technology when line 2 was being installed: they were amazed to see that their control units, including the I/Os, were dismantled and driven by a single PLC.
By starting the Smart Factory project, Industry 4.0 Simatic IT MES integration was made over OPC UCs by collecting data from tens of thousands of sensors . Digitalization and Artificial Intelligence-supported preventive Maintenance Management, one of the firsts in the world, were carried out. 2017-2018
BEFORE
50 operators/8h
19 second cycle time
2.5% error rate
AFTER
4 operators
4 second cycle time
0.6% error rate
ROI in 18 months
Industry 4.0 Project
GE Proficy MES/OEE Project - TIG MES
In order to prepare the VIKO (Panasonic) Factory for the digital transformation of the future, the GE Proficy MES/OEE (Manufacturing Execution System) system , which is the infrastructure of the Industry 4.0 Project in automation machines, was installed.
800-1000 data per minute flows from the sensors of each automation machine (24 stations) to the GE Quickpanels where the OPC Servers are embedded. Real-time data collection, Industry 4.0 infrastructure MES application and Siemens S7-300 PLCs were integrated with ERP by communicating via GE QuickpanelGE Proficy Historian, which is the best-in-class data recording software for over 15+ years , works perfectly. 2011-2012.
What is True MES/MOM Infrastructure?
A real MES/OEE application communicates with the communication of the PLCs of the machines with the OPC servers through the OPC servers, and is collected on the Big Data-Big Data Historian server with tens of thousands of data streams, and real-time monitoring of reports such as OEE and Error Analysis is provided. Isn't it amazing!
OPC Server Communication
OPC (Open Platform Communication) Server communication is a standardized, interoperable method used in industrial automation to exchange real-time data, alarms, and historical information between hardware (e.g., PLCs) and software (e.g., SCADA, HMIs) between different manufacturers.
PLC Data Collection - PLC Veri Toplama
PLC data acquisition is the process of extracting, recording, and storing real-time operational measurements (e.g., sensor information, cycle times, and fault codes) from industrial control units. It enables predictive maintenance, process optimization, and OEE tracking.
OEE (Overall Equipment Efficeiency)
It is an indispensable component of an MES (Manufacturing Execution System) system. The best businesses in the world are striving to increase their OEE value to 85% in order to be in the Champions League.
With tens of thousands of data streams per minute, OEE is created by storing Big Data on GE Historian. Real-time monitoring is done by monitoring the number of parts per shift, performance level, cycle time deviation, stoppages, and error causes. In this system, where operators follow their own performance, an 8% increase in efficiency was achieved on a shift basis.
OEE - Availibility Performans Quality
Since Availibility data, which constitutes the first sub-component of OEE , also includes machine downtimes, Performance data, which is the second component formed by small small stops from thousands of sensors, and Quality data, which is the last third component, also provides very important data for Fault Analysis reports.
Fault Analysis
Reports filtered from millions of data coming from the sensors of the machines form the infrastructure for Fault Analysis (Fault Analysis Reports) Predictive Maintenance.
Predictive Maintanence - Kestirimci Bakım
Vital for the business, it also shows the technical team the frequency of repeated sensor error information of which malfunction and provides emergency, daily, weekly, monthly periodic maintenance data on how much the working parts of the machine are at risk or not. It is a great process for business maintainers and production managers to improve the OEE performance of the business.
T.I.G Authentig MES
In addition, the magnificent T.I.G Authentig MES data collection and reporting system was installed for 56 injection machines in VIKO. 2014
Switch Socket Assembly Automation
Automation Systems
For the first time in Turkey, Viko (Panasonic) Switches and Sockets were produced flawlessly with robots and autonomous machines without human touch, and a Full Socket Assembly Automation line with an annual capacity of 12 million was established. 2007-2008
By starting the Smart Factory project, GE Proficy MES integration was made via OPC UCs and Siemens PLCs by collecting data from tens of thousands of sensors . Digitalization and Artificial Intelligence-supported preventive Maintenance Management, one of the firsts in the world, were carried out. 2011-2012
BEFORE
125 operators
90 second cycle time
2.1% error rate
AFTER
4 operators
0.7 second cycle time
0.6% error rate
ROI in 18 months
Automation Systems
For the first time in Turkey, the welding automation of LED Panel Aluminum frames was carried out with a high-efficiency 6-axis KUKA welding robot. It is an automation system with a four-stage security system.
The interesting thing is that embarking on an automation project without method and line balancing analysis is contrary to my automation methodology so far. Yes, you are right, sometimes a very, interestingly critical process creates a bottleneck in the field and you are under pressure, and you have to carry out a project for a solution in a very short time.
It was necessary to weld very smooth aluminum spots to the corners of the aluminum frames used in the production of LED panels. Human adolenomia is not suitable for continuous akynak.
Due to the projects that my design team worked on, they could spare limited time as support.
In this case, I made myself a table from crates and started working in the welding area in the field. I prepared a draft on paper. Thinking of four separate automatic locking stands and putting a 6-axis robot in the middle; Since it was operator and robot work, the operator and the robot should not come into contact for safety reasons.
I explained the project to the mechanical teams, I drew the robot and table axes with tapes on the floor. I gave rough drawings of the security cage locations and retractable doors. In fact, I made all the drawings, albeit rough, with millimetric sensations. The project was commissioned in 1 month. The funny thing is that the card that will enable the robot and the welding machine to communicate is defective, the output supply time is 6 weeks, my automation chief, we sent a dry contact signal to the robot and ran it.
Realization date 2018
