Sewse c&c-over view

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Sewse c&c-over view

  1. 1. A CMM Level 5 Company C & C System Over View Harness General Terminology Manufacturing Steps C & C System Sub System Overview
  2. 2. A CMM Level 5 Company General Terminology What is Harness ? Harness is a composite electric circuit of automobile. It works as nervous system of a vehicle Harness Operations Cut & Crimp Cut Crimp Splice Part Fitting Sub Assembly Assembly Inspection Packing & Dispatch
  3. 3. A CMM Level 5 Company APPLICATION OVER VIEW This system computerizes Wire Harness manufacturing and integrates the manufacturing process such as C&C production schedule, Optimization process, lead wire C&C instruction and C&C production output. PURPOSE OF THE SYSTEM DEVELOPMENT Improvement of control accuracy Reduction of the office work load Reduction of manual operation time Stable manufacturing The best operation instruction Introduction of C&C
  4. 4. A CMM Level 5 Company International VAN Terminal C&C Server C&C ClientsLaser Printer C&C System System Composition Komax Networked Machine
  5. 5. A CMM Level 5 Company C&C SYSTEM (Network Overview) C&C Server (SQL Server 2K) Lead Stores HP LaserJet 8150 C&C Client PDT Barcode Scanner C&C Planner C&C Client & WPCS Format Generator HP LaserJet 8150 TEC PRINTER (For EFU Tkt) C&C Client LAN WPCS Enabled Wire processing machines DHS Server (SQL Server 2K)
  6. 6. A CMM Level 5 Company Sub System Over View 1. Send & Receive Data Sub System 2. BOM Maintenance Sub System 3. C & C Daily Production Schedule (CPS) Sub System 4. Optimization Sub System 5. Production Output Report Sub System 6. Master Files Maintenance Sub System 7. CUP Sub System 8. Stock Taking Sub System 9. GBG Sub System This system consist of following modules
  7. 7. A CMM Level 5 Company Send & Receive Data Sub System provide the functions to get BOM data and to import to the C&C system. Send & Receive Data Sub System BOM -: Bill Of Material for C&C System is the data prepared by SWS for design of new products. B O M D a t a H e ig h t D a t a B O M fo r C & C S y s t e m
  8. 8. A CMM Level 5 Company BOM List Of Not Set Height C&C Clients List of not set MachineNo. Wire Type Change List New Wire List New Terminal List New Material List BOM Upload List BOM Upload Error List Product BOM Splice BOM Material Detail BOM MH BOM Material BOM Circuit BOM Circuit Grp Detail Terminal Material Set Machine No Height BOM
  9. 9. A CMM Level 5 Company O DENGRP.TXT N CPS Height Upload List Height WON CPS CircuitBOM Local Height C KYOZKN.TXT TANZKN.TXT HGTKAN.TXT Height Upload
  10. 10. A CMM Level 5 Company BOM Maintenance Sub System BOM Maintenance is to add some production condition (Ex Machine Condition) BOM data can be displayed, modified, added, deleted and copied. BOM related Lists are displayed. (Circuit BOM List, Terminal Usage List and so on.
  11. 11. A CMM Level 5 Company Output Report for BOM sub system Report Name Report Explanation Product BOM List When you want to confirm the Product BOM, use this list. Circuit BOM List When you want to confirm the Circuit BOM, use this list. Wire Requirement List When you want to check the ‘Wire Requirement’ per all product No / specific product No / CPS , use this list. Terminal Requirement List When you want to check the ‘Terminal Requirement’ per all product No / specific product No / CPS , use this list. Terminal Usage List When you want to check the ‘Terminal Combination Pattern’ per all product No / specific product No / CPS , use this list. Wire & Teminal Usage List When you want to check the ‘Wire & Terminal Combination Pattern’ per all product No / specific product No / CPS , use this list. Material Requirement List When you want to check the ‘Material Requirement’ per all product No / specific product No / CPS , use this list.
  12. 12. A CMM Level 5 Company C & C Daily Production Schedule (CPS) Sub System Production Schedule C&C Schedul e Production Schedule List List 1 4 7 2 5 8 3 6 (1) (2) (3) Output CPS Report CPS Arrangement The Registration of C&C schedule is necessary to keep the C&C System based on the production schedule. CPS Sub System includes the function to register the C&C schedule for scheduling staff according to customer purchase order. C&C start date and issue date You should input issue date every “Lot No” or “Work Order No” when you register the C&C schedule. Each C&C start date and short code is set by C&C system automatically. Decision of C&C start date You can specify the L/T in every process pattern. * L/T abbreviation for “Lead Time”. Single Wire L/T Splice processing L/T Non Single Wire processing L/T (Pre Insert, Manual Crimping) Special Wire L/T
  13. 13. A CMM Level 5 Company How to get a start date in each process (1). Single Wire L/T = Single Wire L/T (2). Splice Wire L/T = Single Wire L/T + Splice processing L/T (3). Non Single Wire L/T = Single Wire L/T + Non Single processing L/T (4). Special Wire L/T = Special Wire L/T (Ex.)  1. Single Wire L/T 1 day  2. Splice processing L/T 1 day  3. Non Single Wire processing L/T 2 days  4. Special Wire L/T 4 days  Issue Date Nov 15 Nov 11th Nov 12th Nov 13th Nov 14th Issue Date Single Wire 1 Splice Wire 1 2  Non Single Wire 1 2 3 Special Wire 4 CPS Sub System
  14. 14. A CMM Level 5 Company Optimization Sub System BOM EFU Extraction Check List 1 2 3 (1) EFU Extraction (2) Optimization (3) Machine working load Arrangement CPS Data 4 EFU (4) Report Output The brief of Optimization Sub System is as the follows. Daily working data is extracted from CPS data and after optimization EFU data is prepared. EFU data is ordered in consideration of change time or EFU No or Process Pattern. Optimization related reports are available. (Daily Working Report, Work Load List and so on
  15. 15. A CMM Level 5 Company Manual Optimization You can arrange the auto optimization result manually. Moving inside the same machine The order change on the specific machine Moving between the machines EFU data moving between the specific machines Optimization Sub System Work Load List Work Load Detail List C&C Instruction Sheet Lead Set-up report Daily Working Report Wire Requirement List Wire Preparation List Terminal Requirement List Terminal Preparation List Material Requirement List EFU Sheet (Normal) EFU Sheet (Emergency) This list is to confirm the man-hour and set-up time and production quantity per shift and machine. (This list is used for machine working load arrangement.) This list is to confirm the circuit information and man-hour and set-up time and production quantity per shift and machine. (This list is used for machine working load arrangement.) EFU This is a daily report to fill the EFU order and defect information and actual height information. This list is used for wire preparation. Wire type, wire size, wire flex, production quantity is outputted. This list is used for wire preparation. Wire type, wire size, wire flex and production quantity is outputted per machine..   This list is used for terminal preparation.   Directions sheet for C&C operator. This is EFU for emergency. Specify the product no and circuit, and output the EFU one by one.
  16. 16. A CMM Level 5 Company Production Output Report Sub System Daily Working Report (1) Input Actual Result EFU Half Ticket (1) Refer to the Actual Result Progre ss Status Screen You Input actual C&C result of operator by the Daily Working Report.You register actual C&C result of EFU by using barcode reader. Refer to the C&C completion status on the C&C status screen if necessary. Output Reports are as follows. 1.SKT List 2.Efficiency List(per M/C or per Operator) 3.Defect List Status Enquiry is obtained along with the information details regarding the A. Circuit giving Terminal as well as Material Description B . Defect giving the defect quantities corresponding to the defect codes 4.Machine Maintenance List 5. Daily Working Report
  17. 17. A CMM Level 5 Company Master Files Maintenance Sub System We must adjust some manufacture conditions again in this sub system when produces the new product or introduce a new auto C&C machine and so on Standards of the factory can be decided. Standards of machine can be decided. Access limit of user can be decided. (Standard Data) Capacity of factor C&C Machine OperatorTerminal Wire Standa rd Tables (1) Input the standard data Machine Cutting (Type/Size) Manual Cutting (Wire Length) Terminal Material Applicator Pre-Ins Material Wire Bunch Class Wire Bunch Condition Process Machine No Machine Setting Machine Condition Circuit Condition Wire Bunch Size Unnecessary BOM data Change Wire Type Wire Calendar Lead Time Serial No Operator Defect Code Spoilage Code M/C Std Run Time Height Check Screen O/H Terminal Terminal Retention Local Height User ID PGM Function PGM Function Relation Function CTL BOM Others Process Decision Machine Decision Others Working Day Lead Time   Operator Name       User ID/Name PGM ID/Name User and PGM Relation Send & Receive data Sub System CPS Sub System POR Sub System Height Relation System  
  18. 18. A CMM Level 5 Company CUP Sub System Purpose of the CUP subsystem is to introduce an imaginary product using multiple Products which have similar circuit Information common at different level. Common Product is a combination of products which share some common circuit information. Products which share some common circuit information and combine together form a common product, are called component product. Product #A Product #B Product #C Common Circuits in Product #B & #C Common Circuits in Product #B & #A Common Circuits in Product #A & #C Common Circuits in Product #A, B & #C Common Product
  19. 19. A CMM Level 5 Company Stock Taking Sub System This subsystem can support the stocktaking job for C&C area. Prints the stocktaking check sheet. Staffs for stocktaking fill this check sheet with circuit or material quantity in C&C area. There are 4 method for filling the check sheet.  Circuit Group and quantity  Circuit and quantity  EFU Serial No and quantity  Circuit and material quantity
  20. 20. A CMM Level 5 Company GBG Subsystem Unnecessary data that it passed through the specified term is exported to text file and compress. After this, these data is deleted from C&C database.
  21. 21. A CMM Level 5 Company To meet the requirements of SEWS-E (Sumitomo Electric Wiring System Europe) following 2 modules has been added in the Standard C&C System. Module: 1 • STOCK CONTROL SYSTEM ( SEWS-E system ) Module: 2 • MRP SUBSYSTEM ( SEWS-E system ) SEWS-E C&C (System Overview)
  22. 22. A CMM Level 5 Company SWS/UK HEIGHT DATA I.H.S CAD DATA LESZNO DEVA TOPOLCANYRAWICZ CUTTING MACHINE ORASTIE ENG DEPT ENG DEPT ENG DEPT ENG DEPT ENG DEPT MACHINE NETWORK MACHINE NETWORK MACHINE NETWORK MACHINE NETWORK MACHINE NETWORK CUTTING MACHINE CUTTING MACHINE CUTTING MACHINE CUTTING MACHINE LOCAL MRP & LEADS STOCK SYSTEM ASSEMBLY C&C SYSTEM C&C SYSTEM C&C SYSTEM C&C SYSTEM C&C SYSTEM SEWS-E C&C (System Overview) ALBA ENG DEPT MACHINE NETWORK CUTTING MACHINE C&C SYSTEM
  23. 23. A CMM Level 5 Company ASSEMBLY PLANNING ENGINEERING I.H.S C.A.D HEIGHT DATA CST PROCESSES Standard C&C System MPS DATA PRODUCT B.O.M.s HEIGHT DATA MACHINE NETWORK D.H.S MPS MACHINE TYPE DATA CIRCUIT BOM DATA STOCK DATA MRP RESULT MACHINE OPTIMISATION DATA TICKET DATA MACHINE NETWORK DATA BUILD SCHEDULES C&C SYSTEM LEAD STORE STOCK SYSTEM ASSEMBLY ALSO NON NETWORK MACHINES SEWS-E C&C (Data Flow)
  24. 24. A CMM Level 5 Company C&C Assembly CPS MRPCut Lead Stock Build Schedule (Planned qty ) Safety Stock DecreaseIncrease DHS Assembly MPS CC masterfile CC optimisation Order Policy Modifiers ( LT / Calendar etc ) Availability Reports Decrease Daily working report & Tickets MRP Check Report LEAD STORES C&C PROCESS Suggested Cutting Schedules After MRP BOOK IN BOOK OUT KITTING BUILD SCHEDULES SEWS-E C&C (Stock/MRP Logic)
  25. 25. A CMM Level 5 Company SEWS-E C&C (MRP Suggestion) MRP Suggestions As on >> 10/02/03 << Common Product or Product Number : TOYDRLH ( example ) Bundle Qty MRP Suggestions A Side B Side BECC CCVC 10/02/2003 17/02/2003 24/02/2003 Safety Stock Arrears Current Future 1 Week 1 Week 17/02/2003 #PO P79 0 60 240 240 240 60 0 0 240 0 240 60 240 #R1 JAV 0 60 240 240 240 60 0 0 240 0 240 60 240 $NE JAT 0 60 240 240 240 60 0 0 240 0 240 60 240 $NL JAU 0 60 240 240 240 60 0 0 240 0 240 60 240 $QE Q43 0 60 240 240 240 60 0 0 240 0 240 60 240 $QT Q17 0 60 480 480 480 60 0 0 480 0 480 60 480 $QU Q18 0 60 480 480 480 60 0 0 480 0 480 60 480 %Z3 #ZE 0 60 240 240 240 60 0 0 240 0 240 60 240 %Z3 &EA 0 60 360 360 360 60 0 0 360 0 360 60 360 %Z3 JAW 0 60 240 240 240 60 0 0 240 0 240 60 240 %Z3 Z62 0 60 240 240 240 60 0 0 240 0 240 60 240 %Z3 ZHU 0 60 240 240 240 60 0 0 240 0 240 60 240 *1 *2 0 60 480 480 480 60 0 0 480 0 480 60 480 JJJ PM1 0 60 240 240 240 60 0 0 240 0 240 60 240 JJJ PM4 0 60 240 240 240 60 0 0 240 0 240 60 240 JJJ PMZ 0 60 240 240 240 60 0 0 240 0 240 60 240 P64 P80 0 60 240 240 240 60 0 0 240 0 240 60 240 P65 P81 0 60 240 240 240 60 0 0 240 0 240 60 240 PNK PNM 0 60 240 240 240 60 0 0 240 0 240 60 240 PP4 PMW 0 60 240 240 240 60 0 0 240 0 240 60 240 R47 R86 0 60 480 480 480 60 0 0 480 0 480 60 480 R48 R52 0 60 480 480 480 60 0 0 480 0 480 60 480 0 0 6600 0 6600 1100 6600 0 0 2400 0 2400 400 2400 0 0 1440 0 1440 300 1440 0 0 2760 0 2760 400 2760 0 0 6600 0 6600 1100 6600 8 6 8 22 Total Sub Circuits Total Circuits Sub Circuits Quantity Grand Total Total Single Circuits Total Splice Circuits Past Due Suggestions Total Quantity Single Circuits Quantity Splice Circuits Quantity Circuit Details MPS Schedule Stock Profile Build Schedule Both Ends Common Crimp Common Circuit Version Code MPS Scheduled Line Issue dates from DHS MRP Suggested Cutting Quantity and Date MRP Suggested Cutting Quantity outside of 5 Day Lead Time Cut Date 03/02/2003 Cut Date 10/02/2003 Cut Date 17/02/2003
  26. 26. A CMM Level 5 Company SEWS-E C&C (MRP Status) MRP Status As on >> 10/02/03 << Common Product or Product Number : TOYDRLH ( example ) Bundle Qty MRP Suggestions A Side B Side BECC CCVC 10/02/2003 17/02/2003 24/02/2003 Safety Stock Arrears Current Future 1 Week 1 Week 17/02/2003 #PO P79 0 60 240 240 240 60 0 0 480 300 0 0 0 #R1 JAV 0 60 240 240 240 60 0 0 480 300 0 0 0 $NE JAT 0 60 240 240 240 60 0 0 480 300 0 0 0 $NL JAU 0 60 240 240 240 60 0 0 480 300 0 0 0 $QE Q43 0 60 240 240 240 60 0 0 480 300 0 0 0 $QT Q17 0 60 480 480 480 60 0 0 960 540 0 0 0 $QU Q18 0 60 480 480 480 60 0 0 960 540 0 0 0 %Z3 #ZE 0 60 240 240 240 60 0 0 480 300 0 0 0 %Z3 &EA 0 60 360 360 360 60 0 0 720 420 0 0 0 %Z3 JAW 0 60 240 240 240 60 0 0 480 300 0 0 0 %Z3 Z62 0 60 240 240 240 60 0 0 480 300 0 0 0 %Z3 ZHU 0 60 240 240 240 60 0 0 480 300 0 0 0 *1 *2 0 60 480 480 480 60 0 0 960 540 0 0 0 JJJ PM1 0 60 240 240 240 60 0 0 480 300 0 0 0 JJJ PM4 0 60 240 240 240 60 0 0 480 300 0 0 0 JJJ PMZ 0 60 240 240 240 60 0 0 480 300 0 0 0 P64 P80 0 60 240 240 240 60 0 0 480 300 0 0 0 P65 P81 0 60 240 240 240 60 0 0 480 300 0 0 0 PNK PNM 0 60 240 240 240 60 0 0 480 300 0 0 0 PP4 PMW 0 60 240 240 240 60 0 0 480 300 0 0 0 R47 R86 0 60 480 480 480 60 0 0 960 540 0 0 0 R48 R52 0 60 480 480 480 60 0 0 960 540 0 0 0 0 0 13200 7700 0 0 0 0 0 4800 2800 0 0 0 0 0 2880 1740 0 0 0 0 0 5520 3160 0 0 0 0 0 13200 7700 0 0 0 8 6 8 22 Past Due Suggestions Total Quantity Single Circuits Quantity Splice Circuits Quantity Circuit Details MPS Schedule Stock Profile Build Schedule Total Sub Circuits Total Circuits Sub Circuits Quantity Grand Total Total Single Circuits Total Splice Circuits Both Ends Common Crimp Common Circuit Version Code MPS Scheduled Line Issue dates from DHS MRP Suggested Cutting Quantity and Date + Emergency 2 qty MRP Suggested Emergency 1 Quantity added to Current ad-hoc tkts made Cut Date 03/02/2003 Cut Date 10/02/2003 Cut Date 17/02/2003
  27. 27. A CMM Level 5 Company SEWS-E C&C (Stock System Leads Flow) CC BUILD SCHEDULES KOMAX LEAD STORES SPLICE SETS & SINGLE SETS SUB ASSEMBLY HARNESS ASSEMBLY NETWORK & NON NETWORK SINGLE SETS SPLICING & SPLICE SETS 98% MINIMUM ACCURRACY 98% MINIMUM ACCURRACY MRP CALCULATION
  28. 28. A CMM Level 5 Company SEWS-E C&C (Data Maintenance) • SAFETY STOCK MAINTENANCE AT FAMILY LEVEL ( CST PLANNER ) • SLOW MOVING STOCK MONITOR MAINTENANCE ( CST PLANNER ) • CST BUILD SCHEDULE MAINTENANCE 98% ( CST PLANNER ) • STOCK ACCURACY 98% ( LEAD STORES ) • MRP CHECK AND ANALYSIS ( CST PLANNER ) • MEASURES OF PERFORMANCE ( CST PLANNER ) • MACHINE CONSTRAINTS DATA (CST PLANNER )
  29. 29. A CMM Level 5 Company SEWS-E C&C (Stock Processing) • BAR CODE TRANSACTIONS • BOOK IN FROM KOMAX , SINGLE / SPLICE LEADS • SUB ASSY LEADS DIRECT TO SUB ASSY AREA • MANUALLY BOOK IN LEADS FROM OTHER FACTORY • BOOK IN SUB ASSEMBLY LEADS AFTER PROCESSING • SCANNER DOWNLOAD CONVERTS BUILD SCHEDULES INTO STOCK QTY • CIRCUIT AVAILABILITY TO CHECK STOCK • CYCLE COUNTING TO MAINTAIN STOCK ACCURACY ( MIN 98% ) • BOOK OUT PRODUCTS OR CIRCUITS / SINGLE OR SPLICE • CIRCUIT COMPARISON FUNCTION TO FIND ALTERNATIVE CIRCUITS • BOOK IN FROM ASSEMBLY AREAS
  30. 30. A CMM Level 5 Company SEWS-E C&C (Stock Processing) • PROGRAM THAT CREATES CUTTING SEQUENCE • PROCESSES “SETS” OF HARNESSES • DESIGNED FOR DAILY / WEEKLY CUTTING • SEQUENCE LOGIC BASED ON MINIMUM CHANGEOVERS • ALLOWS MANUAL OPTIMIZATION TO M/C SEQUENCE • “ SETS “ TRACKING BY LINE ISSUE DATE • AUTO CPS FROM DHS SYSTEM • CREATES COMMON CIRCUIT OPTIONS • MRP GENERATED CUTTING SCHEDULE • LEAD STOCK VISION • SAFETY STOCK FUNCTIONALITY • LEAD AVAILABILITY REPORTS • SLOW MOVING STOCK MONITOR • LEAD MATCHING FUNCTIONALITY • BAR CODE SCANNING TRANSACTIONS • STOCK COST INTERFACE WITH DHS
  31. 31. A CMM Level 5 Company End Of Slide Thank You

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