Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
PUBLIC INFORMATION
PEMSA: Automotive Paint Plant Unlocks
I...
2Pintura y Ensambles de México, S.A de C.V..
Agenda
 Project Objective
 Scope
1. Hardware and Networks update
2. Softwar...
3Pintura y Ensambles de México, S.A de C.V..
Project Objective
4Pintura y Ensambles de México, S.A de C.V..
Copyright © 2011 Rockwell Automation, Inc. All rights reserved. 4
MCP5
MCP3
M...
5Pintura y Ensambles de México, S.A de C.V..
AVI PFCS
Historical
and
Production
DB
SPD receives Costumer Status, all statu...
6Pintura y Ensambles de México, S.A de C.V..
Status before Complexity Project
7Pintura y Ensambles de México, S.A de C.V..
MCP 5
MCP 3
MCP 4
MCP 1
MCP 2
2P500
SQL Computer
Station
Control Room
EMOS
Co...
8Pintura y Ensambles de México, S.A de C.V..
Copyright © 2011 Rockwell Automation, Inc. All rights reserved. 8
MCP5
MCP3
M...
9Pintura y Ensambles de México, S.A de C.V..
Control
• Recipes data control in all production areas (Style-Option-
APA/APD...
10Pintura y Ensambles de México, S.A de C.V..
Copyright © 2011 Rockwell Automation, Inc. All rights reserved. 10
MCP5
MCP3...
11Pintura y Ensambles de México, S.A de C.V..
Infrastructure Server
VLAN MCPs VLAN Proc.
Control Room
EMOS
Control Room
EM...
12Pintura y Ensambles de México, S.A de C.V..
Configuration and clients
Data Base Services
Production Data
Base
Historical...
13Pintura y Ensambles de México, S.A de C.V..
Complexity system view
14Pintura y Ensambles de México, S.A de C.V..
 Data information received from Customer:
 Do-all files in excel format ar...
15Pintura y Ensambles de México, S.A de C.V..
D7
E
E1 G
FB
F G1
G2
I
D2
D3
D4
B&W Delivery to
PEMSA
Delivery
Sequence
Deli...
16Pintura y Ensambles de México, S.A de C.V..
Logistics
•Direct communication system with the
customer that allows us to p...
17Pintura y Ensambles de México, S.A de C.V..
Logistics
•Scan the box label at the beginning of the
process (when it arriv...
18Pintura y Ensambles de México, S.A de C.V..
D7
E
E1 G
FB
F G1
G2
I
D2
D3
D4
Shipment to
PEMSA B&W Sequence for
painting ...
19Pintura y Ensambles de México, S.A de C.V..
Planner
20Pintura y Ensambles de México, S.A de C.V..
SPD System
21Pintura y Ensambles de México, S.A de C.V..
Quality Graphics
22Pintura y Ensambles de México, S.A de C.V..
Quality Production Report
23Pintura y Ensambles de México, S.A de C.V..
Customer Status STAP
B&W Inventory
Status and Quantities, Traceability of th...
24Pintura y Ensambles de México, S.A de C.V..
Bedliner Project above E-Coat
25Pintura y Ensambles de México, S.A de C.V..
 Reducing finished goods inventory by
50%.
 70% increase in production eff...
26Pintura y Ensambles de México, S.A de C.V..
 PEMSA production is based on the
customers real needs (size and colors).
...
27Pintura y Ensambles de México, S.A de C.V..
Thank you!
¡Gracias!
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
PUBLIC INFORMATION
Thank you for participating!
Please rem...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
We care what you think!
 On the mobile app:
1. Locate ses...
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PEMSA: Automotive Paint Plant Unlocks Information, Gains Flexibility and Efficiency

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The PEMSA plant in Mexico supplies Chrysler painted truck components. Challenged to shift from painting two products in seven colors to over 1,200 variations in 22 colors, the plant deployed a recipe-based production control system leveraging FactoryTalk VantagePoint.® The system automated inventories and leveraged ERP system connections to increase visibility drastically. Time required to process typical components dropped from 24 to 9 hours. Direct communication, automated processing and information collection have improved production efficiency 70 percent.

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PEMSA: Automotive Paint Plant Unlocks Information, Gains Flexibility and Efficiency

  1. 1. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. PUBLIC INFORMATION PEMSA: Automotive Paint Plant Unlocks Information, Gains Flexibility and Efficiency Complexity Project November 2013
  2. 2. 2Pintura y Ensambles de México, S.A de C.V.. Agenda  Project Objective  Scope 1. Hardware and Networks update 2. Software update  System process summary  Bedliner project above E-Coat  Benefits
  3. 3. 3Pintura y Ensambles de México, S.A de C.V.. Project Objective
  4. 4. 4Pintura y Ensambles de México, S.A de C.V.. Copyright © 2011 Rockwell Automation, Inc. All rights reserved. 4 MCP5 MCP3 MCP4 MCP1 2P500 MCP2 EMOS MCP6 Scope
  5. 5. 5Pintura y Ensambles de México, S.A de C.V.. AVI PFCS Historical and Production DB SPD receives Costumer Status, all status are available Customer Ethernet Production Controllers Ethernet PEMSA Firewall Router Firewall Router SPD PEMSA Data information collector Scope (Cont.)
  6. 6. 6Pintura y Ensambles de México, S.A de C.V.. Status before Complexity Project
  7. 7. 7Pintura y Ensambles de México, S.A de C.V.. MCP 5 MCP 3 MCP 4 MCP 1 MCP 2 2P500 SQL Computer Station Control Room EMOS Control Room EMOS Smarteye Smarteye Smarteye Smarteye Smarteye Smarteye Smarteye Smarteye Microsoft SQL RSSqlTM RSLinx® VB Application FTP Service FTP Sap Wonderware Intouch RSLinx® RSLogixTM 5000 MCP 6 Architecture before Complexity Project
  8. 8. 8Pintura y Ensambles de México, S.A de C.V.. Copyright © 2011 Rockwell Automation, Inc. All rights reserved. 8 MCP5 MCP3 MCP4 MCP1 2P500 MCP2 EMOS MCP6 Ethernet topology before Complexity Project
  9. 9. 9Pintura y Ensambles de México, S.A de C.V.. Control • Recipes data control in all production areas (Style-Option- APA/APD-Color-Bed Liner). • Exchange of data information between controllers assured. Control • Master Controller at EMOS Control Room was implemented to be able to modify styles to be processed and in line data change required by production. Control • Integration of new device net bar codes. • Pokayokes integration. Control • HMI visualization reconfiguration for new styles. • Tracking of pick up boxes in all processes. Control current status
  10. 10. 10Pintura y Ensambles de México, S.A de C.V.. Copyright © 2011 Rockwell Automation, Inc. All rights reserved. 10 MCP5 MCP3 MCP4 MCP1 2P500 MCP2 EMOS MCP6 Current Topology
  11. 11. 11Pintura y Ensambles de México, S.A de C.V.. Infrastructure Server VLAN MCPs VLAN Proc. Control Room EMOS Control Room EMOS Wonderware Intouch RSLinx RSLogix 5000 ControlRoom EMOS MCP5 Smarteye Smarteye Smarteye Smarteye Smarteye Smarteye Smarteye Smarteye Smarteye MCP2 MCP3 MCP62P500MCP1MCP4 FactoryTalk ® Transaction Manager Professional Microsoft SQL Server SAP – FTP Services VantagePoint® FactoryTalk® View Site Edition StandAlone COSTUMER REMOTE Master Current Architecture
  12. 12. 12Pintura y Ensambles de México, S.A de C.V.. Configuration and clients Data Base Services Production Data Base Historical Data Base Applications FactoryTalk Transaction Manager VantagePoint Data Services Control Technology AB Controllers FactoryTalk® Live Data AB Controllers FactoryTalk View SE Software solution
  13. 13. 13Pintura y Ensambles de México, S.A de C.V.. Complexity system view
  14. 14. 14Pintura y Ensambles de México, S.A de C.V..  Data information received from Customer:  Do-all files in excel format are received twice every day.  This Do-all file was modified or updated any time.  SPD on line sequence delivery list from Costumer to deliver pick up boxes.  Production planning:  Was controlled from status G, to process the sequence delivery to the Costumer.  Production was divided in 4 blocks per day considering the current inventory status of boxes at process and in the finished product (PT) warehouse.  Logistics requested are critical requirements to production.  There was not visualization of others status at costumer plant and in the PEMSA process.  Control Inventory Limitations.  Production management:  Was based in the JIT .xls format program ,where logistics process manually, the data received from Costumer and production planning. Logistics status before Complexity Project
  15. 15. 15Pintura y Ensambles de México, S.A de C.V.. D7 E E1 G FB F G1 G2 I D2 D3 D4 B&W Delivery to PEMSA Delivery Sequence Delivery to Costumer Batch of 12 boxes Batch of 12 boxes Customer Priorities Sec a1 Sec a2 Sec 24 hrs from D2 to G1 9hrs PEMSA Production on sequence Body FRAME Paint shop Delivery FINAL Line Exit Final Line Costumer Process (Before)
  16. 16. 16Pintura y Ensambles de México, S.A de C.V.. Logistics •Direct communication system with the customer that allows us to program and deliver the units on time. Logistics •We collect information from the secondary label and relate to primary label (cab) to determine the characteristics of the box. Logistics •Status review of the cabs in our customer facility to verify PEMSA adequate inventory. Logistics Current Status
  17. 17. 17Pintura y Ensambles de México, S.A de C.V.. Logistics •Scan the box label at the beginning of the process (when it arrives to PEMSA). Logistics •Update the B&W inventory based in the box characteristics. Logistics •Pick list are generated from the input boxes (B&W) to feed the production line based on priorities and availability, blocks of color and B&W. Logistics Current Status
  18. 18. 18Pintura y Ensambles de México, S.A de C.V.. D7 E E1 G FB F G1 G2 I D2 D3 D4 Shipment to PEMSA B&W Sequence for painting on PEMSA Shipment to Customer Lote de 12 Unidades 12 Units Batch Customer Priorities Sec a1 Sec a2 Sec 24 hrs From D2 to G2 9hrs PEMSA production on sequence Body Pint TRIM FINAL Construction Current Customer Process Flow
  19. 19. 19Pintura y Ensambles de México, S.A de C.V.. Planner
  20. 20. 20Pintura y Ensambles de México, S.A de C.V.. SPD System
  21. 21. 21Pintura y Ensambles de México, S.A de C.V.. Quality Graphics
  22. 22. 22Pintura y Ensambles de México, S.A de C.V.. Quality Production Report
  23. 23. 23Pintura y Ensambles de México, S.A de C.V.. Customer Status STAP B&W Inventory Status and Quantities, Traceability of the Process (E-coat, Primer, Color, Reworks, Bedliner) Quality (Reprocessing, SPOT, Rescue) Finish Product Inventory PEMSA Shipment System Process Summary
  24. 24. 24Pintura y Ensambles de México, S.A de C.V.. Bedliner Project above E-Coat
  25. 25. 25Pintura y Ensambles de México, S.A de C.V..  Reducing finished goods inventory by 50%.  70% increase in production efficiency.  Better communication with our customers.  B&W Real Inventory.  Problems like robot crashes, unpainted boxes, etc are gone. These type of problems could cost between 30 min to 1 hour stop production (30 boxes per hour aprox).
  26. 26. 26Pintura y Ensambles de México, S.A de C.V..  PEMSA production is based on the customers real needs (size and colors).  Avoid the shipment of units with a wrong color to our end customer.  Better communication in our whole plant (Production, Logistics, Maintenance, etc.).  Easier integration of new products with a most robust system.  Primer, Base and Clear consumption was decreased by 45% in bedliner boxes.
  27. 27. 27Pintura y Ensambles de México, S.A de C.V.. Thank you! ¡Gracias!
  28. 28. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. PUBLIC INFORMATION Thank you for participating! Please remember to tidy up your work area for the next session. We want your feedback! Please complete the session survey!
  29. 29. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. We care what you think!  On the mobile app: 1. Locate session using Schedule or Agenda Builder 2. Click on the thumbs up icon on the lower right corner of the session detail 3. Complete survey 4. Click the Submit Form button 29 Please take a couple minutes to complete a quick session survey to tell us how we’re doing. 2 3 4 1 Thank you!!

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