Auto body geolocation, safety sensors preventing malfunctions, an Internet of Things application analysing and accelerating painting phases in real time, wearable technology keeping man and machine in perfect sync, augmented reality, an innovative system controlling energy consumption, added flexibility and every part of the process coordinated in the cloud by J-Suite, the “avatar” of the auto body paint plant. These are just some of the advantages of Smart PaintShop.

1. COLLABORATION BETWEEN
HUMAN AND MACHINE
FOR A SAFER AND MORE
PRODUCTIVE ENVIRONMENT
SURCAR CANNES 2017

2. WINNER
INNOVATION AWARD
CANNES, June 29th-30th 2017

3. 3
2005
900
Kwh/job
2010
450
Kwh/job
2017
270
Kwh/job
2017
SMART
PAINTSHOP
ENERGY
INDEPENDENCE DAY
OBJECTIVE
ACHIEVEDA
ESTIMATED DATE:
16TH JUNE 20201
ACTUAL DATE:
16TH JUNE 20171

4. Smart Paintshop
Strategic areas of Smart Paintshop
Project:
 Smart Design – Geico’s internal process
with the aim at drastically shortening
paintshop delivery
 IOT System – Sensors and computing
capabilities on equipment will allow the
collection and analysis of data thus
resulting in a more efficient paintshop
 Production Flexibility - Technologies that
will allow the whole plant to adapt to
production needs
 Smart Plant Management - Technologies
that will allow the cooperation between
man and machine inside the paintshop
 Smart Energy Management System - 4
SMART
PAINTSHOP
Smart DESIGN
IOTSYSTEM
PRODUCTIONFLEXIBILITY
SmartPlant
Management
SmartEnergy
ManagementSystem
J-SUITE

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6. Smart Design involves different aspects of the
engineering, from the design and simulation to the
costification. The integration of the design tools
gives the opportunity to pursue strategic objectives,
such as:
 Shorter paintshop delivery
 Cost reduction
 Generate and aggregate all the information and
the data about the plant
 Possibility of having a faster feedback from
Geico during the proposal period
 Increasing the installation efficiency on site
 Virtual Offline Commissioning
6
Smart DESIGN

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8.  bodyGeolocalization: in-plant body
geolocalization with GPS Indoor technology.
 Smart Process Modules: Sensors systems used in
functional equipment packages in order to
automatically control parameters and to prevent
malfunctioning
 Quality Control: Advanced Analysis detection
using specific scanning tool
8
IOT SYSTEM

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bodyGeolocalization
The Client will be able to:
 Locate single bodies inside the
plant
 Analyze the process flow
 Integrate innovative features
Advantages:
 The system does not require
cables
 Reduction of installation time for
areas where the geolocalization
equipment is implemented
 Model information directly on
the body not on the equipment
for a more precise and reliable
information
Future evolutions:
 Operators safety will increase by

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Smart process Modules
Advantages:
 Ready-to-use process modules
with embedded sensors able to
monitor and predict the
functioning of the equipment
avoiding future breakdowns
 Reduction of installation time
 Plug and play (virtual
commissioning)
 Predictive maintenance:
 improved spare parts
management
 reduced maintenance time
 Self-adaptive production
capacity
 improved energy
management

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Innovative Quality Control
Advantages:
 Human/machine cooperation thanks to
augmented reality
 Human-eye-like identification of surface
defects
 Real time analysis
 Possibility to find defects between 0,2 mm
and 0,3 mm
 Fast scanning system: the system can
effectively work with 2 cameras
 Scanning area is 500 mm with resolution of
0.1 mm/pixel
 High frequency scanning (30 frame per
second)
Future evolution:
 Upstream integration to autonomously

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13. Production flexibility consists to adapt the plant to its
real productivity and needs for better efficiency and
flexibility. In order to implement such plans Geico has
been developing the following systems:
Elene
Booth: The Elene allows the booth’s ventilation and its
operation to be adjusted to the active length actually
required for the production that is in progress.
Oven: (ELastic ENergy Ecology) The Elene oven
option allows the oven’s ventilation and its length to
be adjusted to that actually required for the production
that is in progress.
J-Hive: J-Hive consists in the development of an
eight-sided cell designed for painting both the interior
13
PRODUCTION FLEXIBILITY
 Elene (ELastic ENergy Ecology): booth’s and oven’s
ventilation and its operation is adjusted according to the
length actually required for the production
 J-Hive: evolution of an eight-sided cell designed for
painting both the interior and exterior of a body in one
single station
 Smart Conveyor (AGV): Automatic Guided Vehicle for
movimentation of car bodies and skids inside the plant

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ELENE
Advantages:
 Energy, costs and emission
reduction
Future evolution:
 Information will be
communicated by the
sensors on the body
allowing the elaboration of
different production
scenarios

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J-Hive
Advantages:
 Compact footprint
 Tailor-made layout (octagon
frame)
 Reduction of investment and
operating costs
Future evolution:
 Modular production model for
mass customization

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Smart CONVEYOR AGV
Advantages:
 Smart and flexible
transportation for car bodies
and materials
 Efficient and flexible production
 Reduction on investments and
management costs
 Simpler and faster installation
and commissioning (virtual
commissioning)
 Highly convenient for mass
customization plant
 Easy implementation for
brownfield projects
Specific data for a touch up area:
 1 AGV for paintshop capacity
up to 40 JPH
 2 AGVs for paintshop capacity

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18.  Smart Supply Management (Tagging) system: tags for
unloading and uploading warehouse/stock, geolocalization, J-
Doc (connected to ERP and PLM)
 Smart Maintenance: wearable system using augmented
reality
 Human Machine Interface: wearable devices for enhanced
human machine cooperation and safety
 J-Doc: management software for technical data about plant
machineries and components + other integration
implemented on PLC
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Smart Plant Management

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Smart Maintenance and HMI
Wereable devices integrated with
augmented/virtual reality
Advantages:
 Real time information for
operators’ training and for
client’s plant management
 Real time communication
human/machine in order to
support manual operations
 Easier maintenance
interventions
Future evolution:
 The interface will be able to
collect documentation and data
about the startup process,

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J-Doc
Advantages:
 Digital management of the client’s
technical documentation
 Data collection during the
commissioning phase
 Easy access to digital
documentation via bar code
positioned on equipment
Future evolution:
 Access via IOT Systems
 Innovative HMI

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22.  Energy management system: data collection system on energy consumption, used
to adapt the plant and pursue cost efficiency
 J-Power: software for simulation of scenarios on energy requirements and
alternative resources availabilities on specific locations
 VOC Intelligent Sensing Oven: Sensors system for oven solvent level control
22
Smart Energy Management System

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Energy Management System
Advantages:
 Live displaying of consumptions
and cost of energy
 Highlighting differences between
the actual and forecasted
consumption
 Elaboration of consumption
statistics along the different plant
lines
Future evolution:
 PLC embedded plant management
software
 Integrate with Smart Process
modules in wireless mode

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J-Power
Advantages:
 Evaluation of the impact
of different scenarios for
the application of Geico’s
Pardis technologies
Future evolution:
 Constant feedback to the
customer in order to
facilitate future plants
updates or investments

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VOC Intelligent sensing oven
The VOC Intelligent Sensing
Oven is a new technology that
supplies fresh air to the oven
only according to actual
demand (VOC measurement
sensors).
Advatages:
 Reduction of energy
consumption due to the
lower amount of fresh air to
be treated

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27. The J-Suite is a Manufacturing Operations Management (MOM)
software, which gives the possibility of not only fully integrating
clients’ systems but also digitalizing manufacturing operations
in order to improve efficiency, flexibility and time-to-market.
The Advantage of the project is:
 Data Analytics thanks to the digitalization and collection of
data during the manufacturing proccess
Future evolution of the project:
 Integrated manufacturing operations management and
platform for comprehensive management of the whole plant,
also providing feedback to Geico for Smart Design
27
J-SUITE

28. J-Suite
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J-Suite

29. Overall Project overview
29
SMART
PAINTSHOP
Smart DESIGN
IOTSYSTEM
PRODUCTIONFLEXIBILITY
SmartPlant
Management
SmartEnergy
ManagementSystem
J-SUITE
BodyGeolocalizationa
Smart Process Skida
Innovative Quality Controla
ELENE
J-Hive
Smart Conveyor (AGV)
Smart Maintenance and HMI
J-Doc
Energy Management System
J-Power
VOC Intelligent Sensing Oven

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