Quality System Upgrade

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PROJECT

Pentium-Based Architecture Development

CUSTOMER

Chrysler Corp.

Objectives

  • Identify and evaluate alternatives for implementing a PentiurnlNT-based system for Chrysler Information Systems.
  • On an operational level, develop a method of containing problems wIThin the workstation where a defect occurs, or inside a group of workstations within the assembly. Ensure that defects are attributed to the proper vehicle through a tracking image that is integral to the vehicle 10.
  • Develop and implement a ‘next-generation’ ALS (Automatic Une Stop) system that is PentiurnlNT-based and user-friendly, and that offers effective and efficient operator communications. Provide appropriate hardware and software to interface ALS WITh the quality system.
  • Using Belvedere as the beta SITe, complete the transition from the existing PLC-based Quality Alert System (QAS) to the new PentiurnlNT-based system. Integrate the new archITecture WITh related plant systems.
  • Concurrently, engineer and implement an automatic vehicle identification system (AVI), and new plant communications protocols.

Description

QAS encompasses the floor and middleware layers of Chrysler’s quality system, linking operator actions, tool faults, and other events with supervisor actions, upper-level controls, and plant communications. Its apex is the corporation’s Performance Feedback System, a mainframe application that maintains quality documentation for assembly operations.

Design Systems identified practical alternatives and evaluated
with the customer, the best design concepts. The advanced
PC-based QAS architecture uses Allen-Bradley’s SoftLogix 5

“Bottom Line” Results

  • Successful installation at Belvedere in 1998 paved the way for corporate-wide implementation.
  • Among the most direct benefits is the ability to reconfigure the QAS system remotely from most anywhere on the globe.

Material Handling

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PROJECT

Engine Delivery System Upgrade

CUSTOMER

GM Lansing Delta Engine Plant

Objectives

  • Determine the root causes of conveyor downtime and malfunctions, particularly with problems related to misreads of barcodes and miscounts.
  • Reduce the required maintenance on the system.
  • Improve the maintainability of the system .

Description

Engines exit the final assembly line and are transferred to a power and free delivery conveyor. The engines are hung from the power and free carriers using chains. The existing optical barcode reader had difficulty reading the engine barcodes due to differences in product size and the swaying motion of the engines. As a result, engines were often routed improperly.

Design Systems, Inc. identified the problems and developed concept solutions and budget estimates for client review. GM was impressed with the concepts and approved the program. Design Systems worked with the plant to implement the new concepts as follows:

Replace the optical barcode reader system with a Radio Frequency-based system. RF tags were mounted to the stable carrier, rather than the swaying engines.

Remove all of the tracking software from the Modicon processor. This dramatically reduced the size of the PLC program, and made it easier to understand and maintain.

Improve the existing Modicon PLC Logic to enhance reliability.
Develop a “User-Friendly” operator graphics interface to improve maintainability and system visibility.
Combine the functions of the operator graphics interface and the RF tracking system into a single computer.

“Bottom Line” Results

  • The project was completed on time, and on budget.
  • I The power and free conveyor performs very well with a dramatic reduction In falkns.
  • I The system Is more user-friendly and maintainable.

Electrical and Controls Engineering

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Design Systems, Inc. provides customers with the unique ability to emulate and verify their controls logic for new or modified systems

Capital Investment Savings by Improving Project Start-Ups

Emulation uses a Programmable Logic Controller (PLC) connected to the graphical features of a detailed simulation model, replicating the production environment. The PLC, responds to inputs received from the model just as it would on the production floor. Reciprocally, the model responds to the PLC outputs, as would the actual control devices present in the factory. All inputs and outputs of the system are validated using emulation, including manual operator stations and hardware interlocks.

The Design Systems, Inc. emulation process establishes a virtual environment for a material handling system with full functionality, feedback, and a 3D graphical view of the complete system. It also creates representations of control panels and allows the common field faults to be applied to the PLC logic. This environment allows an entire material handling system to be analyzed in an office setting without impacting production. We also have the ability to easily stage test scenarios and run the system at full volume to verify capabilities.

Emulation provides a variety of checking mechanisms to allow the customer and the project partners to verify that the deliverables are in compliance with the scope of work, proper standards, and control methods. It also affords the ability to interconnect and effectively test associated control and diagnostic hardware prior to plant installation, further reducing start-up time and providing additional cost savings.

Design Team Integration

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PROJECT

Tray Management

CUSTOMER

Siemens
Electrocom L.P

Objectives

  1. Partner with Siemens Electrocom L.P in the development of an integrated design approach to tray management (TMS) that could be implemented in facilities nationwide.
  2. Bring together talent from diverse disciplines to most effectively address the many issues regarding mechanical systems, controls, ergonomics, material flow and facility compatibility.
  3. Evolve detailed simulation strategies that would allow viable alternative ideas to be understood and evaluated by the customer, quickly and thoroughly.

Description

A Design Team that included representatives from Siemens Electrocom L.P. and Design Systems’ Mechanical, Manufacturing, Controls and Simulation Groups combined their resources in this landmark project.

Optimization layouts created by engineers on the team demonstrated the potential and nature of product flow throughout individual facilities.

DSI engineers provided detailed construction plans and other vital support documents.

“Bottom Line” Results

  • The Integrated Design Team Approached has provided a very effective strategy for engineering these postal systems.
  • Design Systems, Inc. takes great pride in teaming with clients. We have been an effective engineering partner for Siemens since 1996.

Comprehensive Program Management

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PROJECT

Design and Implementation of Conveyors, Paint Process Equipment and IS

CUSTOMER

Chrysler Windsor “NS” Minivan Plant

Objectives

  1. Create a comprehensive, ‘walls-in’ paint shop including conveyors, all paint process elements, and support systems.
  2. Implement and commission all shop equipment.
  3. Engineer and integrate all information systems.
  4. Use simultaneous engineering and advanced scheduling techniques to achieve a zero launch curve.

Description

Design Systems functioned as Lead Consu~ant and Project Manager for this landmark greenfield facility. Included in the scope of work was the design and implementation of a system for applying zinc phosphate and electrocoat, a dual-pass cure oven, and dual robotic sealers. Six airhouses for facility-wide ventilation management were included, as was the design and installation of decks for sealer and electrocoat sanding.

In concert with the paint process line, Design Systems consulted on control panels, and distributed information systems for data acquisition related to process variables.

The conveyor configuration is a skid system, with inverted power and free conveyors, an Air-B-Dip, and various lift tables, power roll tables and cross transfers. A skid washer and power and free carrier washer are also key to the system.

The PC-based DIS monitors every process variable within the paint shop, generates real-time process variables and creates historical trending. It provides clear, at-a-glance system status, and exceptional process traceability.

Following system installation, DSI performed comprehensive check-out, and performed point-by-point verification of motors and motor control panels associated with process equipment and conveyors throughout the facility.

“Bottom Line” Results

  • The goal of 8 z.o Launch Curve was achieved.
  • First-day production reached its target of 1500 jobs.
  • The launch Is repded by Chrysler Corp. 81 the most successful of its kind to date.

Arc Flash Analysis

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Design Systems, Inc. continues to be a leader in assisting the manufacturing community with plant specific safety programs to ensure employee safety and company compliance. One such area that can literally mean the difference between life or death is compliance with regulations NFPA 70E and CSA Z462 dealing with Arc Flash Safety

Design Systems Arc Flash Analysis Services:

Design Systems’ talented group of electrical engineers will lead your organization through the entire Arc Flash process to ensure your plant employees are safe and your company fully meets all the OSHA and industry consensus standards. Programs are comprehensive and may include:

  • Written electrical safety program
  • Employee training program or ‘train the trainer’ class
  • Electrical power system analysis and panel labeling
  • Up-to-date one line drawings
  • Mitigation reports
  • Arc Flash Hazard Category reduction; reduce cost of maintenance
  • Energized electrical work permits
  • Personal Protective Equipment (PPE) requirements
  • Engineered solutions and installed solutions
  • Electrical safety audits and maintenance
  • Ongoing Arc Flash training and electrical safety program training for your employees.

“BOTTOM-LINE” RESULTS:

  • Employee Safety
  • OSHA Compliance
  • Ongoing Training
  • PPE Requirements

Work Safe, Work Smart…