Vehicle Manufacturing Automation System Introduction, Part 1 - PMC

1. Vehicle Manufacturing
Automation System
Introduction
Part 1 - PMC
Tallrain / Sep 2016

2. 1 – What’s
…PMC?

3.  PMC = Process Monitoring and Control.
 For vehicle manufacturing, we have OEM(Original Equipment
Maker) PMC and MES PMC. OEM PMC is usually installed at
Central Control Room, for remote monitoring and control.
MES PMC is usually installed in Plant Floor, for production line
monitoring, not engaged in control.
 PMC integrates with conveyors/devices via PLC.

4. 2 - Why…
PMC?

5.  PMC is used mostly to monitor production exceptions, esp. Machine
faults.
 In Stamping Shop, Stamping Machines and Moulds cost over tens of
million dollars. Plant capacity is limited by Machine availability.
 Purchasing, installation, debugging of large machines take 1-2 years.
The easiest way of extending capacity is to use machines more
efficiently.
 Some Welding Plants use Robots for 90% of operations.
 At Explosion-proof Area of Paint Shop, equipment can only be
monitored from remotely.
 At General Assembly Shop, PMC overview page helps managers and
engineers to find issues from complex process.

6. 3 – PMC
…Boards

7.  PMC boards break levels down:
Plant >> Shop >> Line >> Station,
differ status with colors.
 PMC boards can also show data
pushed from MES, such as Target,
Pass Rate, Shift, Welcome Message.

8. 4 – PMC
…Analysis

9.  PMC generates Stop Time Summary
Report of Stations and Machines, to
help to find bottleneck of daily
operations.
 PMC collects data as OEE(Overall
Equipment Effectiveness) input, to
help to find key control points of
production.
0
20
10 10
0
50
20
30
0
10
20
30
40
50
60
OP10 OP20 OP30 OP40 OP50 OP60 OP70 OP80
Daily Stop Time Report of Line X
97%
93%
97%
95%
93%
90%
95%
92%
86%
88%
90%
92%
94%
96%
98%
1月 2月 3月 4月 5月 6月 7月 8月
OEE Trend Report of Line X

10. 5 – PMC…
Architecture

11. OEM PLC
MES PMC SERVER
OPC
Server
Remote
I/O
CP卡
IT Network
Control Network
PMC Board
Driver
OEM PLC
MES PMC SERVER
OPC
Server
Remote
I/O
CP卡
IT Network
Control Network
Board
Drvier
 Architecture 1:
OEM PLC collects
data, and then
output via SCADA
software such as
WINCC.
 Architecture 2:
MES collects data
from OEM PLC, and
then output via
reporting platform.

12. 6 – PMC
…Products

13. Vendor Module Platform
ROCKWELL PMC RTVIEW
SIEMENS SCADA WINCC
GE SCADA CIMPLICITY
CEC FIS KEPWARE
IGNITION SCADA KEPWARE

14. Thank you!
1