APIC Systems AVI, Tracking Image, & Quality Alert System 2 TNG Training Presenter: Marcus Sternberg Last updated: 2007 Jan

Agenda 1. Overview 2. AVI 3. Tracking Image 4. QAS Workcell

APICS Lots of products Automatic Vehicle identification AVI subsets: Colorwheel, Mix bank Tracking Image, QAS/ALS Mistake proofing APICS Mercury PFCS

Development and Implementation APICS Development arm ASLM Assembly System Launch Management Implementation arm of all APICS products FIS Implementation As required

APICS

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APIC web site http://apics.intra.chrysler.com/

ASLM / FIS implementation

AVI / QAS Main Components Automatic Vehicle Identification - Barcode reader - Floor PLC - Panelview Station sequencing & Automatic line stop - QAS WCC - QAS configuration database server (HMI) Tracking image - Floor PLC - Panelview

AVI Used to provide bar code label data to the Floor QAS PLC. Main Backup

AVI Components

AVI Reader Function Read job mounted bar code labels Decode the scanned information Forward the information to the tracking image application within the PLC

Associated Stack Lights Flow Bar code is sent to the AVI/VMS driver located in a PLC associated with that particular point AVI/VMS driver validates the bar code Label is sent to QAS Tracking Image Application Barcode Readers and Associated Stack Lights

Empty Carrier Photoeye Function Determines if there is an empty carrier If empty, photoeye sends a signal to the AVI/VMS driver that there is no vehicle on the carrier Empty Carrier Photoeye

Video Camera/Monitor Function The camera is positioned to display the bar code or VIN In the event of a No Read, the line will stop and the label will display on the monitor, allowing the operator to manually enter the number on the PanelView

Video Camera/Monitor

AVI Stack light

QAS Provides vehicle sequencing that displays vehicle ID on PFS terminals in sequencing stations Sequences vehicle IDs for marriage with tool data in PFCS Provides Automatic Line Stop (ALS) capability to contain problems within a station or production zone

QAS Components

Floor QAS PLC Function Contains the QAS Tracking Image Application and the AVI/VMS driver used by QAS Can be implemented into the conveyor PLC or existing on its own PLC with up to 4 other other tracking images (“Concentrator PLC”)

Flow Receives the bar code label data from the AVI/VMS reader, then the bar code data is sent to the AVI/VMS driver. The driver sends the bar code label data to the QAS Tracking Image Application. The Floor QAS PLC sends the tracking image to the QAS WCC for every 1-foot of travel on the conveyor.

Floor QAS PLC Panel

Encoder Function A device that uses the mechanical rotation caused by the conveyor movement to produce an electrical signal. The electrical signal of the encoder is converted to feet, which is used to determine the distance the conveyor has traveled for vehicle position.

Flow The encoder generates an electric signal due to the rotation caused by the wheel or gearing. This electric signal, when combined with an initial tracking image, monitors the position of a vehicle along a conveyor.

Meshing

Two variations of encoder mountings Ceiling Mounted Encoder and Friction Wheel Skillet Conveyor Encoder

Very High Speed Counter Module (VHSC) Function Performs the high-speed count of the encoder pulses. The module is an intelligent block transfer I/O module that interfaces with the Floor QAS PLC

Flow Counts from the module’s memory to a designated area in the Floor QAS PLC processor data table using Block Transfer instructions The VHSC module counts encoder pulses because of the high rate at which the encoder sends its pulses

VHSC Module

PanelView Function Provide the user with an array of screens that display tracking image information, such as bar code numbers and location on the conveyor in feet

Purpose Operators can use this information to verify that the proper vehicle is in station and to back up reader input in the case of a fault or No Read condition Communicate with the Floor QAS PLC for all information requests and use block transfers to send and receive information

PanelView and Associated Control Panel

QAS Workcell Function A PC dedicated to running the QAS SoftLogix5 engine. The SoftLogix5 engine is a software implementation of an Allen Bradley PLC-5 The QAS WCC is responsible for sending job arrival messages to PFCS, where it is married to tool data for the appropriate station

QAS Compaq WCC

Tool Controller Function Gather input data from station tools and send this data to PFS through PFCS

Flow Tool data is sent to PFCS, where it is married with the ID of the job received from QAS This marriage is sent to PFS for logging Tool Controller

QAS WCC Configuration ACC Known as “Human Machine Interface for QAS workcell” Contains the configuration database used to update the Realtime database Specifies the location of stations, tools, and terminals along the line where arrival messages are to be generated Identifies warning points, timer values, conveyor interlocks and annunciation device locations for ALS and Timed PFS stations

ALS Station Hardware Station Lights- Used to announce ALS events to local operators Restart Pull Cords- Used to restart the line after an automatic line stop, bypassing the condition that caused the line to stop PFS terminals also annunciates ALS conditions, bypass vehicle in station, restart line and show product ID

Green: The SoftLogix engine is running in the Remote Run mode. Grey: The SoftLogix engine is running in the program mode. Black: The SoftLogix engine is stopped and in the program mode. Yellow: Uploading or Downloading of information. Flashing Red: Fault Condition