HMI & PLC
Upgrades
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Wal*Optical is a lens
manufacturing company for the
ophthalmic industry specifically
to the affiliated Wal*Mart
Stores.
Wal*Mart contains multiple
manufacturing lines for lens
processing. A particular system,
UL60, is a complex integrated
automation system which allows
one operator to produce lenses
through the blocking, cutting,
polishing and coating process.
Compared to the conventional
equipment which can take 6 to 7
personnel with limited
throughput, the UL60 is the
primary focus at Wal*Mart
encompassing over 60% of the
labs production.
The system is actually divided
into 5 processing stations with
automated material handling pick
and place system in-between,
enclosed in one structure. The
processing station are:
Blocking, Roughing, Finishing,
Polishing and Coating. Each
processing station contains from
2 axis of controlled motion to
5. Pneumatic actuators,
Inverters,
electrical/servo/stepper motors,
pneumatics/electrical I/O,
barcode readers, RFID readers,
live video imaging system, UV
light/compound dispensing and
curing system as well as custom
engineered devices.
In
order to ramp up production,
MotionFab and Wal-Mart analyzed
the manufacturing equipment and
process to produce a strategy
that would allow increased
throughput. The areas of
improvement were: System
reliability, System physical
speed, Operator/System
efficiency, and manufacturing
process.
The system reliability posed a
problem in production downtime
from hardware repairs, software
bugs and end-product quality.
MotionFab reviewed the system
and produced a failure listing
prioritized
by mean-time-to-repair and cost
analysis. MotionFab determined
one of the major problems was
problem
determination. Technicians
efficiently determining where
the problem occurred and area to
troubleshoot. Other areas varied
from control logic errors to
hardware mechanical design
issues. The following were some
of the corrective actions:
-
MotionFab redesigned the
error and reporting for the
system to point technician
more effectively in
the problematic area.
Motionfab also developed
some utilities to help log
and effectively diagnose
interrupts with statistics.
-
MotionFab also provided
readily available parts in
the high wear rate
components in close
locations by 24 hour depots.
This minimized the lead time
to get components to the
customer and installed.
-
Preventative maintenance
schedules and actions were
reviewed to ensure optimal
operating conditions.
-
The control logic error were
addressed and delivered as
part of the new upgrade
PLC software package and
install along with process
improvements. The control
logic changes also affected
I/O. New schematics and
electrical panel layouts
were designed.
The system speed was analyzed to
determine the subsystems and
manufacturing process
"bottle-neck". A review of the
system allowed MotionFab to
provide a solution to the
process in motion control speeds
as well as process engineering.
The operator job functions were
to queue up jobs as well as
initially inspect the end
produce quality. MotionFab
determined to improve the
operator abilities was to
improve the time the operator
has to perform the functions.
Motionfab redesigned the HMI
specific to the operators needs
with orientation and moving
multiple autonomous actions onto
one. Technical Personnel would
access security controlled
screens for troubleshooting and
preventative maintenance.
Manufacturing process was
reviewed and utilities developed
to aid Wal-Mart in determining
future analysis. production
statistics and failure mode
analysis automated from the data
collected from the system. These
were custom designed and
developed for the system.
MotionFab developed the changes
off-site and tested in
simulation. MotionFab backed-up
all configurations and system
information for completion of a
back-out plan if needed.
MotionFab scheduled with Wal*Mart
the upgrades and combined both
software and hardware changes
simultaneously to minimize
production interruption.
MotionFab tested the initial
system and followed through with
the other system upon
satisfactory realization of the
changes.
In
short, MotionFab provided:
System and manufacturing
cost analysis and
identification of
improvements
Project and Risk management
Development life cycle
Deliverables in electrical
schematics, mechanical
drawings, Software and
control system Install with
CD, Contacts, Project
Management and related
documentation.
Minimal production downtime
and Seamless Integration
