Vehicle Manufacturing Automation System

IntroductionPart 1 - PMC

Tallrain / Sep 2016

1 – What’s…PMC?

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.

2 - Why…PMC?

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.

3 – PMC…Boards

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.

4 – PMC…Analysis

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

5 – PMC…Architecture

OEM PLC

MES PMC SERVER

OPCServer

RemoteI/O

CP卡

IT Network

Control Network

PMC Board

Driver

OEM PLC

MES PMC SERVER

OPCServer

RemoteI/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.

6 – PMC…Products

Vendor Module Platform

ROCKWELL PMC RTVIEW

SIEMENS SCADA WINCC

GE SCADA CIMPLICITY

CEC FIS KEPWARE

IGNITION SCADA KEPWARE

Thank you!

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