2. 6/10/15 2
• What FMF is Not: FMF is not an application
• What is FMF? FMF is a set of standards:
- error-proofed manufacturing instructions
- instruction execution engines
- communication protocols
- data models
- physical interfaces and devices
- common multilingual operator’s interfaces
- applications and best practices
- configuration and requirements practices
assembled into the end user solution using the modular design.
1 - Pick to Light SD(4pt) & Scan PN
2 – Scan PN
3 – Scan SN (Masked with pattern(s))
4 – Torque (ATLAS Copco and Stanley tools)
5 – Pick to Light HD(16-32pt) & Scan PN
6 – Orders Queue
7 – Programming Devices (EDIXIA)
8 - Print (Label, Document)
9 – Cell Assembly
10 – Confirmation scan (Indexed/masked)
11 – Pick to Light Curtain SD(4pt)
12 – Pick to Light Curtain HD(16-32pt)
13 – Input Test (Circuit continuity)
14 – Torque (Digital I/O)
15 – Vision Inspection (BANNER and Cognex)
16 – EE-Check (IP testers)
… template for new instruction development
3. 6/10/15 3
• What is the main objective of FMF?
The main objective of FMF is to provide standard and manageable manufacturing
execution solutions based on the following principals:
- Assemble reusable modules through common extensible mechanisms.
- Leverage protocol/interface driven design vs. implementation driven design.
- Increase Utilization of Open Protocols and standards for OEMs and
Suppliers. Not to be confused with common application interfaces, OPC for
instance.
- Reduce nr of instances of manufacturing critical custom programmed code
and lines of code executed on computer based systems.
- Reduce nr of instances of manufacturing critical applications executed on
computer based systems.
- Consistency, similar objectives reached through utilization of a similar tools.
- Reduce dependency on various designs of machine controls, and integration
protocols.
- Reduce dependency on IT management of infrastructures, networks, servers,
workstations. (FMF is Deterministic).
- Balanced new development vs. new configuration approach.
- Common mechanism for translation of manufacturing requirements into
system requirements.
4. 6/10/15 4
• Where did FMF come from?
FMF was a product of collective engineering efforts and lessons learned, involving
multiple teams, individuals and VISTEON sites including:
- Canton
- Barcelona
- La Vergne
- Thailand
5. 6/10/15 5
• FMF History:
pre-FMF
- 2004 (1q) Barcelona development and startup of Instrument Panel Assembly line
using ALTA PB2O – OPTO22 – ICONICS
- 2005 (2q) CANTON upgrade and migration from ALTA PB2O clients on Terminal
server Instrument Panel Assembly line to ALTA PB2O server – ICONICS clients.
- 2005 (3q) NITRA - development and startup of Door Panel sequenced solution
using ALTA PB2O server – ICONICS data model and clients.
- 2005 (4q) Halewood - development and startup of Instrument Panel Assembly line
solution using ALTA PB2O server – ICONICS clients.
FMF
- 2006 (1q) Thailand – first FMF development and implementation for Instrument panel
assembly line.
- 2006 (2q) CANTON – upgrade and migration to FMF based solution for multiple
Instrument Panel Assembly lines. Completed in 2007 (4q)
- 2006 (4q) Rennes - development and startup of a Door Panel sequenced solution
using ALTA PB2O server – ICONICS clients and mobile clients.
- 2006 (4q) La Vergne – Consolidation of 2 Rear Console assembly lines to 1 using
FMF based solution.
- 2007 (1q) Barcelona - beginning of migration to FMF based solution.
- 2007 (2q) Smyrna – beginning of migration to FMF based solution.
6. 6/10/15 6
• Where is currently FMF in Visteon Manufacturing Sites?
Sites Nr. of Stations Nr.of FMF Stations
--------------------- ------------------- --------------------------
- Canton 30 30 (+4 new on the way)
- Barcelona 17 17
- La Vergne 22 4
- Smyrna 12 2
- Thailand 11 11
Total: 92 64
About 70+% of Nissan IP and Consoles Manufacturing
Goal: 100%
Bulk of I/O devices in La Vergne and Smyrna consists of AllenBradly controllers. Local controls are ready for standard integration with FMF. Need corporate
to OK it.
7. 6/10/15 7
• Why FMF?
FMF was a result of increasing demand in implemented solutions for:
rapid changes in manufacturing processes relative to:
– error-proofing scenarios
– order processing
– quality tracking
– reduced debug time
– exception handling
– new devices integration
8. 6/10/15 8
• The most important FMF achievement was:
The Ability to perform:
- line balancing
- station changes and rotation
- new station deployment
through a standard consolidated set of configurations vs. custom:
- code development
- configurations
- logic changes
- in multiple applications and hosts
in legacy solutions.
9. 6/10/15 9
• Another important aspect of FMF is:
Openness for integration. Comprehensive set of programming tools allowed complex
integration with diverse set of hardware and equipment manufactures, including:
- Atlas Copco Torque Tool controllers (torque and angle values)
- Stanley Torque Tool controllers (torque and angle values)
- Ethernet Barcode Scanners
- BANNER Vision Sensors (visual inspection control and test results)
- Instrument Panel Electrical Testers
- Allen Bradley DF1 (SLC and Micrologix)
- Various Pick to Light and Pick to Light Curtains solutions.
- BALOG RFID transceivers
- MODBUS supported devices
- Ethernet IP supported devices
- Makita Torque Tool controller (in development)
- COGNEX Vision sensors (in development)
- And many more…
Result - reduction of the middleware application instances
