TOYOTA Shop Floor Application

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TOYOTAShop Floor Application

• Presented by
• Kevin ONeil

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Radio Frequency Identification
Vehicle Tracking System
Mirtec Technologies
Presented by Kevin ONeill
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AGENDA

• Mirtec Technologies
• - Geographical Coverage
• - Services
• - Systems
• - Industry
• - Future
• Project Details
• - Toyota SA
• - Requirements
• - History
• - Project Phases

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AGENDA

• Application
• - Phase 1 Description
• Criteria
• Software and Interface
• EMS Products
• Duration Value
• - Phase 2 Description
• Criteria
• Software and Interface
• EMS Products
• Duration Value
• Costs Benefits
• Competitors
• Conclusion

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Company Details
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MIRTEC TECHNOLOGIES

• System Engineers and Integrators
• Established - 1988
• Services
• Design and Engineering
• Feasibility Studies
• Systems Integration
• Installation
• Commissioning
• Consulting
• Distributors
• Systems
• Batching Systems
• SCADA
• Field bus Systems
• Control and Automation
• Tracking Systems (Since January 2000)

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MIRTEC TECHNOLOGIES

• Industry
• Coal Fired Power Generation.
• Platinum,Gold and Chrome Mining and Refineries.
• Pulp and Paper.
• Automotive.
• Petro-Chemical.
• Food and Beverage.
• Material Handling
• Future
• Radio Frequency Identification

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MIRTEC TECHNOLOGIES

• Location
• Durban South Africa
• Major Industrial City and Port Situated on the
  East Coast.

Map Relation
Offices
Employees
Total 18 employees consisting of System
Analyst's, Engineers and Field Technicians.
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MIRTEC TECHNOLOGIES
Geographical Coverage
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MIRTEC TECHNOLOGIES
Geographical Coverage
Durban
Main Port
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MIRTEC TECHNOLOGIES
Geographical Coverage
Durban
Main Port
Port Elizabeth
Automotive Industry
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MIRTEC TECHNOLOGIES
Johannesburg
Geographical Coverage
Industrial Capital
Durban
Main Port
Port Elizabeth
Automotive Industry
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MIRTEC TECHNOLOGIES
Johannesburg
Geographical Coverage
Industrial Capital
Durban
Main Port
Port Elizabeth
Automotive Industry
Cape Town
Agricultural Sector
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MIRTEC TECHNOLOGIES
Johannesburg
Geographical Coverage
Industrial Capital
Durban
Africa
Main Port
Future
Port Elizabeth
Automotive Industry
Cape Town
Agricultural Sector
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Project Details
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THE COMPANY
SA Manufacturing

• Founded 1961
• Importer, Assembler, Manufacturer and Marketer
  of Motor Vehicles,and Motor Vehicle Parts
  and Accessories.
• Also has the agency for Hino Trucks
• 6700 Employees
• 6 Billion Rands (860 Million) Turnover
• Market Leader for the last 21 years Presently
  24 of South Africa Market Share
• Future plans to export to Australia Therefore
  working towards WCM (World Class
• Manufacturing)
• Plant Production capacity - 500 Vehicles per
  8hr shift.
• Current Production 360 Vehicles per shift (96
  400 per Annum).
• Manufacture 6 Models
• Tazz, Corolla, Camry, Condor, Hi-Lux(Pick
  Up), Hi-Ace (Mini Bus Transporter)

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PLANT LAYOUT PROCESS FLOW
Distribution Yards
A Yard
B Yard
Train
Vehicle Final Line
Body Shop
Paint Shop
Assembly Hall
TOYOTA SA MARKETING (TSB)
TOYOTA SA MANUFACTURING (TSM)
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PLANT LAYOUT PROCESS FLOW
Distribution Yards
A Yard
B Yard
Train
Vehicle Final Line
Body Shop
Paint Shop
Assembly Hall
TOYOTA SA MARKETING(TSB)
TOYOTA SA MANUFACTURING(TSM)
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PLANT LAYOUT PROCESS FLOW
Distribution Yards
A Yard
B Yard
Train
Vehicle Final Line
Body Shop
Paint Shop
Assembly Hall
TOYOTA SA MARKETING(TSB)
TOYOTA SA MANUFACTURING(TSM)
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PLANT LAYOUT PROCESS FLOW
Distribution Yards
A Yard
B Yard
Train
Vehicle Final Line
Body Shop
Paint Shop
Assembly Hall
TOYOTA SA MARKETING(TSB)
TOYOTA SA MANUFACTURING(TSM)
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PLANT LAYOUT PROCESS FLOW
Distribution Yards
A Yard
B Yard
Train
Vehicle Final Line
Body Shop
Paint Shop
Assembly Hall
TOYOTA SA MARKETING(TSB)
TOYOTA SA MANUFACTURING(TSM)
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PLANT LAYOUT PROCESS FLOW
Distribution Yards
A Yard
B Yard
Train
Vehicle Final Line
Body Shop
Paint Shop
Assembly Hall
TOYOTA SA MARKETING(TSB)
TOYOTA SA MANUFACTURING(TSM)
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PLANT LAYOUT PROCESS FLOW
Distribution Yards
A Yard
B Yard
Train
Vehicle Final Line
Body Shop
Paint Shop
Assembly Hall
TOYOTA SA MARKETING(TSB)
TOYOTA SA MANUFACTURING(TSM)
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PLANT LAYOUT PROCESS FLOW
Distribution Yards
A Yard
B Yard
Train
Vehicle Final Line
Body Shop
Paint Shop
Assembly Hall
TOYOTA SA MARKETING(TSB)
TOYOTA SA MANUFACTURING(TSM)
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PLANT LAYOUT PROCESS FLOW
Distribution Yards
A Yard
B Yard
Train
Vehicle Final Line
Body Shop
Paint Shop
Assembly Hall
TOYOTA SA MARKETING(TSB)
TOYOTA SA MANUFACTURING(TSM)
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COMPANY REQUIREMENTS

• Due to the introduction of SAP into TOYOTA , it
  was realized that an Automatic Tracking System
  had to be implemented. The main reason being to
  ensure Real Time WIP (Work In Progress)
  information for use on the shop floor, stock
  control and Financial Management
• To achieved this the ultimate objective would be
  to have the Auto Tracking operational from the
  start of the production process (Body Shop)
  through to Vehicle Distribution throughout the
  country.

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HISTORY

• Job cards Processed Manually.
• Vehicles moved no faster than the paper work
  flow.
• Fitment and distribution planning was done only
  on what had physically reached a workstation.
  With a result - no forward planning.
• Stock holding in the Distribution Yards was 3
  days due to manual paper work processing.
• NO REAL TIME DATA!!!!!

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PROJECT PHASES

• Toyotas decision was to introduce an Auto
  Radio Frequency ID Tracking System within the
  plant and implement this in two phases.
• Phase 1 Paint Shop (Dollies and Hangers)
• Dual purpose installation
• - Tracking of Vehicles
• - Tracking of Vehicle Carriers for
  maintenance purposes
• Phase 2 Complete Process
• Fixed RF Tag on the vehicle throughout
  overall process
• capable of withstanding harsh paint shop
  environment.

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PHASE 1

• Tag Mounting
• - HANGERS - DOLLIES

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PHASE 1
Cycles 1.09 per day 288 per annum
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PHASE 1
Cycles 2.13 per day 563 per annum
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PHASE 1
13.5MHz International standardized frequency

• Products Used

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PHASE 1
13.5MHz International standardized frequency

• Products Used
• RF Tags - HMS 150 HT
• - Quantity 500

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PHASE 1

• RF Tags - HMS 150 HT
• Passive (No Batteries)
• Read/Write
• 736 bytes memory
• Baud Rate 9600
• -40 C to 240 C
• Reusable
• NEMA 6P/13(IP 68)

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PHASE 1
13.5MHz International standardized frequency

• Products Used
• RF Tags - HMS 150 HT
• - Quantity 500
• RF Readers HMS 820
• - Quantity 14

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PHASE 1

• RF Readers HMS 820
• Integrated Antenna
• 4 Input/Output points
• Host Interface (Com 1)
• -RS232/RS422/MUX 32
• Auxiliary RS232 serial port.
• 1000 bytes/sec transfer speed.
• NEMA 4 (IP 66)

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PHASE 1
13.5MHz International standardized frequency

• Products Used
• RF Tags - HMS 150 HT
• - Quantity 500
• RF Readers HMS 820
• - Quantity 14
• Interface module MM80
• - Quantity 1

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PHASE 1

• MM80 MicroMux Bus module
• RS232/RS485 converter
• Mux 32 protocol
• C programmable
• 9600 346K baud communication
• Network up to 32 devices

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PHASE 1

• Software and Interface
• In-house Custom Written Software
• Visual C

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PHASE 1

• Software and Interface
• - 2 Alternate interfaces
• RS232 to Token Ring Thin Client (VTS)
• RS485 (Mux 32) to EMS Data base (Maintance)

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PHASE 1

• Duration Value
• - Total Project 12 weeks
• Cost R600 000(85 000)

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PHASE 2

• Description
• Tracking of Vehicles.
• 96 400 Units per annum.

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PHASE 2

• Description
• Tracking of Vehicles.
• 96 400 Units per annum.

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PHASE 2

• Criteria
• - 6 different models.
• - No common mounting position.
• - Withstand Harsh conditions (200c).
• - Cost lt R35 (5) per Tag.

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PHASE 2
13.5MHz International standardized frequency

• Products Used

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PHASE 2
13.5MHz International standardized frequency

• Products Used
• RF Tags LRP 250 HT-FLX
• - Quantity 96 400 per annum

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PHASE 2

• RF Tags - LRP 250 HT-FLX
• Passive (No Batteries)
• Read/Write
• 48 bytes memory
• Reusable or Disposable
• Adhesive backing
• -40 c to 240 c
• NEMA 6P/13(IP 68)

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PHASE 2
13.5MHz International standardized frequency

• Products Used
• RF Tags LRP 250 HT-FLX
• - Quantity 96 400 per annum
• RF Readers LRP 820-08
• - Quantity 71

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PHASE 2

• RF Readers LRP 820-08
• Read/Write multiple tags simultaneously
• 4 Input/Output points
• Host Interface (Com 1)
• -RS232/RS422/MUX 32
• Auxiliary RS232 serial port.
• NEMA 4 (IP 66)

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PHASE 2
13.5MHz International standardized frequency

• Products Used
• RF Tags LRP 250 HT-FLX
• - Quantity 96 400 per annum
• RF Readers LRP 820-08
• - Quantity 71
• Portable reader Formula 7400
• - Quantity 5

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PHASE 2

• Portable reader Formula 7400
• I.Code Identification
• Read RFID and Barcodes.
• Based on a 486 processor.
• Integrated full RS232 and IrDA Ports

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PHASE 2
13.5MHz International standardized frequency

• Products Used
• RF Tags LRP 250 HT-FLX
• - Quantity 96 400 per annum
• RF Readers LRP 820-08
• - Quantity 71
• Portable reader Formula 7400
• - Quantity 5
• Pass through Gate Antenna
• - Quantity 1
• Interface module MM80
• - Quantity 9

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PHASE 2

• Software and Interface
• RS232 interface with Token Ring Thin Client
  within
• TSM Production Plant.
• RS485 Multi drop Network throughout TSB
  Distribution Yards.Interfaced to TSM via Token
  Ring Gateway.
• Wonderware IN-TRACK software.
• SAP Management System

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PHASE 2

• Duration Value
• (Excluding Software and Token Ring Network)
• Total Project 6 months
• Cost R1.6 million (230 000)
• Tags monthly consumable.

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COSTS BENEFITS

• Phase 2
• Overall Vehicle Tracking Project
• - R9 500 000 (1.357 000)
• Manual data capture redundant
• Real Time/Work In Progress information available.
• Reduction of Stockholding.
• ONE DAY STOCK REDUCTION EQUATES TO R35 (7)
  
• SAVING PER UNIT IN FINANCING COSTS
• 96 400 Units per annum _at_ R35 R3 374 000
  (482 000)

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COMPETITORS

• Siemens
• Baumer Ident
• Impro (SA)
• First two competitors products very expensive
• Third competitor products failed during trials

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CONCLUSION

• It is believed that this VTS project will
• move TOYOTA towards World Class
• Manufacturing.

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Q A

• ?