At the final assembly plant in Saarlouis, Germany, wireless network components optimise the construction of the Ford Focus motor vehicle. Mobile terminals and call buttons that are wirelessly connected to the network increase the efficiency of the material transporters by up to 30%. Furthermore, the WLAN solution ensures greater flexibility and improves occupational health and safety.
Innovations not only in the cars
On average, 1780 Focuses roll off the production line each day in Saarlouis, totalling well over 1,5 million since production began in 1998. Having been twice named 'Car of the Year', this successful model offers the most spacious interior and luggage area in its class and is the only compact vehicle to offer a multilink rear axle. The production of this vehicle is as innovative as the car itself. Continuously improved logistics ensure a free-flowing supply chain through the use of wireless technology.
"Thanks to the cable-free networking, stock levels and the associated production line stoppages have been drastically reduced," says Peter Nowottny, leader of the Mobile Call Board project at the Saarlouis final assembly plant.
Radiowaves have replaced rigid copper cables, and the Mobile Call Board has taken the place of a fixed stock ordering and supply system. Previously, the outgoing version of the Line Feeding System had stationary, cable-connected PCs, from which the forklift drivers had to pick up the transport orders generated by the storage management system. Nowottny summarises the problems with the former solution: "There were often queues at the stationary terminals and the trips to and fro took place mostly without cargo." Nowadays, both waiting times and empty trips are a thing of the past: the utilisation of the forklifts equipped with mobile terminals has risen by up to 30%. Robust wireless connections using Artem's OnAir WLAN technology provide the wireless networking of the mobile terminals with the storage management system.
One button-press
30 000 square metres, making up the relevant 60% of the total factory floor, receive coverage from 24 ComPoints. At the other end, ARtem ComCards wirelessly connect the mobile terminals on the forklifts and so-called 'call buttons' to the optimised logistics system. Also, along the production line, 10 universal clients are installed as call buttons, with their switches connected to radio modems. A button-press by one of the assemblers sends a data message to the server containing the necessary part numbers and the specific location that they are required. A small light on the button indicates that the message has been generated. Once the server has confirmed the request, it sends a signal to the light in the button to start blinking. At the same time, the server generates the appropriate transport order and sends it to the mobile terminal on the forklift that is responsible for that particular area. Once again, signal lights controlled by the system also indicate the job-processing status.
Nowottny expects a big increase in flexibility once the number of wirelessly integrated transporters increases further from the current six machines. Their fixed allocation to specific assembly areas can then be widened or removed altogether, resulting in a transporter being able to undertake multiple roles in a larger area.
For more information contact Errol Mann, Integr8 & Autom8, 086 128 8668, www.i8a8.co.za
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