5 november 2008 Evoluon - Eindhoven OMRO N LCIA Bram Kale European Engineering manager. OMRON Omron Europe B.V

5 november 2008 Evoluon - Eindhoven OMRO N OMRON Industrial automation Japanese multinational employees 5.8 Billion in Euro Industrial automation products PLC’s Card-Readers Human Machine Interface Motion Control (OYMC) Vision & ID systems Timers & Counters Sensors

5 november 2008 Evoluon - Eindhoven OMRO N Engineering SMT automated production Assembly Manual production LCIA assembly

5 november 2008 Evoluon - Eindhoven OMRO N LCIA Assembly Description LCIA – Low Cost Intelligent Automation is a system for effective manual production, where manual stages, simple control systems and clever tools are integrated to a flexible, productive and high quality method of assembly.

5 november 2008 Evoluon - Eindhoven OMRO N

5 november 2008 Evoluon - Eindhoven OMRO N LCIA assembly Productivity improvement Reduction of Quality problems Increase production Flexibility Focus points:

5 november 2008 Evoluon - Eindhoven OMRO N 2. Synchronization of Chain of Processes 1. Consequent Elimination of Waste [Muda] Anchor in the line set up Drivers of the system LCIA assembly -Overproduction -Waiting time -Transportation -Processing -Inventory -Motion -Product defect

5 november 2008 Evoluon - Eindhoven OMRO N LCIA assembly Balance the strong points of the worker Flexible Intelligent Accurate Repetitive with those of the machine

5 november 2008 Evoluon - Eindhoven OMRO N Basics of LCIA assembly Flexible number of operators in line Make many products in one line Quick change over time Easy to train operators Standing style operations Productivity Quality Flexibility One-piece flow, fixed # WIP Standardized labor Ergonomically sound everything in a fixed place (5S) LCIA solutions Fool-proof (Poka-Yoke) solutions Efficient work allocation Teamwork Paced to (stable) cycle time Easy & not disturbing material replenishment from outside Visual management Paced to (stable) cycle time Standardized labor Fool-proof (Poka-Yoke) solutions Flexible number of operators in line Standing style operations

5 november 2008 Evoluon - Eindhoven OMRO N LCIA effect Productivity Quality Flexibility CQM1 PLC assembly line: Cycle time reduction of 250%

5 november 2008 Evoluon - Eindhoven OMRO N LCIA effect Productivity Quality Flexibility From: Manual visual check Avg 63 customer complaints per year Estimated >1000 defects per year Wrong color Intensity To Low cost vision system Zero defect & Inspection time reduction (20 sec) No illumination LED allways on

5 november 2008 Evoluon - Eindhoven OMRO N LCIA effect Productivity Quality Flexibility 35 different product in one line with change over time <30 sec.

5 november 2008 Evoluon - Eindhoven OMRO N Design process Line design very early in the product development process Use Process FMEA to predict possible fault causes Decide necessary tools based on FMEA level Detailed Line Design and assembly Test runs, measure designed cycle times, optimization

5 november 2008 Evoluon - Eindhoven OMRO N Thank you for your attention