BENEFIT FROM OUR AUTOMATION EXPERTISE …...Itochu Machine-Technos Corporation phone +81 3 3506 3528...

CIMCORP IN A NUTSHELL

Automation technology company Cimcorp supplies robotic solutions for managing material flows in production and distribution environments. Cimcorp’s purpose-built systems, software and services improve the profitability and competitiveness of its customers’ businesses.

The Cimcorp group – which consists of Cimcorp Oy in Finland and RMT Robotics Ltd in Canada – has become a leading supplier worldwide to the tire industry, and is also regionally strong as a supplier to the food & beverage and postal services sectors. The group has around 220 employees and has delivered almost 2.000 robotic systems across five continents.

CIMCORP OY Satakunnantie 5, FI-28400 Ulvila, FINLANDphone +358 2 6775 111, fax +358 2 6775 [email protected]

North AmericaRMT Robotics Ltd. (a Cimcorp Oy company) 635 South Service RoadGrimsby, Ontario, Canada L3M 4E8phone +1 [email protected]

Brazil, ParanaM2 Concepts Solucoes Empresariais LTDAphone + 55 41 [email protected]

China, Suzhou, Jiangsu Province,Matromatic Technologies (Suzhou) Co., Ltd.phone +86 512 67533255 www.mae.cn

India, ChennaiLarsen & Toubro Limited, LTM Business Unitphone +91 44 2249 1932 www.larsentoubro.com

Japan, TokyoItochu Machine-Technos Corporationphone +81 3 3506 3528www.itcmt.co.jp

Russia, MoscowLLC International Representative House, First Link phone +7 495 223 6839 [email protected]

South Korea, Seoul EKL Korea Corporationphone +82 2 2242 [email protected]

United Kingdom, DevizesLogistics Planning Ltdphone + 44 (0)5601 [email protected] www.logisticsplanning.co.uk

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BENEFIT FROM OUR AUTOMATION

EXPERTISECimcorp is a total solution supplier and systems integrator you can rely on for innovative design, robust technology and rapid support.

Pioneer in roboticsCimcorp has supplied thousands of gantry and linear robots to clients in over 30 countries. More than 500 of these robots operate in the tire industry, handling some 1.5 million tires per day.

Tire industry know-howWith many years’ experience in materi-al handling automation for tire production and distribution, Cimcorp – along with its subsidiary, RMT Robotics – is dedicat-ed to providing best-of-breed, integrated systems that enhance productivity,improve quality and secure savings. This industry knowledge is the founda-tion of Cimcorp’s success in serving the tire-manufacturing sector.

Our strengths

• Highlyexperienced, turnkey solution supplier to the tire industry

• One-stop-shopwithtotal system integration

• Provensolutionsfrom component manufacturing to the shipping docks

•Modularsystemsfor fast installation and start-up, simple maintenance and flexible expansion

• Worldwidesalesand support operations

As an independent systems integrator, our scope of supply covers the equip-ment required to handle the total material flow. Our solution provides seamless integration for the ultimate in production efficiency – that’s why we call it Dream Factory.

Cimcorp has supplied a significant number of greenfield and brownfield installations for tire manufacturers world-wide. Although a greenfield site offers the ideal platform for Dream Factory, the fact that this system is created from independent modules means that partial automation of existing facilities is also simple to implement.

INSTAllATIONS SUPPORTEd

wORldwIdEComprehensive customer supportCimcorp is committed to providing high-quality support, precisely when and where it is required. Whether you choose to outsource your maintenance or provide it in-house, we will tailor support services to suit your needs.

Training: Full training is provided during the commissioning phase and as required for new staff.

Helpdesk: Cimcorp provides a fast and expert helpdesk, 24/7 for your convenience.

Maintenance: We will tailor a preventive maintenance program to suit the needs of your application.

Spare parts: Cimcorp provides total spare parts support.

Operational support: If you outsource the operational support for your system to us, we provide comprehensive engineering expertise at your site, allowing you to focus on your business.

Modernization: A partnership approach to your logistics allows us to analyze the changing needs of your business and propose ways to modernize or upgrade your system.

Cimcorp provides reliable customer support and

builds long-standing partnerships with clients to ensure maximum system

uptime.

Please turn the page to see the whole Dream Factory concept

dREAMFAcTORyFully automated handling for tire manufacture and distribution

Total material flow control with comprehensive tire data tracking













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Kai TuomisaariVice President, Sales and Marketing, Cimcorp

Cimcorp’s systems allow 100% availability of components, guaranteeing full capacity for the tire-building machines.

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RAW MATERIALCOMPONENT

Proven technologyOur robots have been developed to handle a range of work envelopes (gantry spans) and load weights. This proven technology is the platform on which we continuously develop application-specific solutions. Our latest innovation, Cimcorp+, is a new generation of more ecological robot. Faster in operation and lighter – yet still robust – in structure, the Cimcorp+ series offers 30% higher performance combined with 40% lower energy consumption, as well as minimized maintenance needs.

Tire-handling expertiseOur overhead gantry robot fulfills many functions – buffer storage, sortation, palletizing and order picking – making it a remarkably versatile and cost-effective solution. Gantry robots also utilize space in a highly efficient manner, releasing footprint in factories for production.

In the tire industry, gantry robots are used extensively in sorting and buffering operations for both green tires and finished tires. Linear transfer robots, developed for connecting remote points and also capable of handling heavy loads, are mainly used for the transfer of green tires from the building machines to the spray stations and for loading of the curing presses. Cimcorp also supplies ancillary equipment – including stackers, destackers, lifts and conveyors – to form fully integrated systems.

Gripper know-howThe development of application-specific grippers for robots is a core discipline within Cimcorp. Our universal tire gripper can pick anything from a single tire to a complete stack, with the flexibility to handle a wide range of tire types, diameters and heights – from PCR (Passenger Car Radial) to OTR (Off-The-Road) and also green tires.

Cimcorp’s robots – including our latest series, Cimcorp+ – have been developed specifically to meet the demanding materials handling needs of the tire industry. They can be applied flexibly for automation in both brownfield and greenfield plants. CuSTOMeR benefITS

Output is maximized by ensur-ing 100% availability of tires for all processing and testing machines.

100% tire traceability and process data management are ensured by highly effective control systems.

Production flexibility is optimized through the ability to make tire type changes and new tire additions automatically at any time.

Product quality is improved through gentle and accurate handling.

Customer satisfaction is enhanced through error-free and fast robotic tire picking and shipping.

financial and space savings are achieved through reduced WIP (Work In Process).

www.cimcorp.com

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dREAM FAcTORy

A revolutionary systemWith our Dream Factory solution, we offer comprehensive automation tech-nology for tire manufacturers, providing total control of the material flow and precise, real-time data for production and inventory management. By automat-ing material handling throughout the factory, Cimcorp’s systems optimize throughput, minimize buffer stocks and make dynamic use of available space. Computer control of all automation units means that individual tires can be tracked through the whole process.

Innovative processesAs management of the flow of green tires to the curing area has a significant impact on a tire plant’s output, Cimcorp’s solutions manage the lot sizes of the build-ing machines, minimize green tire buffer stocks and provide JIT (just-in-time) supply of tires from building to curing. In this way, our automatic systems ensure 100% tire availability to keep the curing presses operating.

Dynamic handlingAfter curing, tires are collected from the presses automatically by a trench conveyor system, which transports them to the trimming area and then to the inspection process. Cimcorp’s systems provide total flexibility for the finishing area. With tires stored directly on the floor, the storage area can be dynamically recon-figured to handle any combination of tire types. Using Cimcorp’s gantry robots, batches of tires can be formed as requir-ed to feed the uniformity testing machines.

Rapid dispatchOnce testing is complete, tires are sorted by type and classification before being automatically palletized. The pallet loads are then stored fully automatically in the ASRS, from where they are retriev-ed to meet customer orders, being transferred to delivery trucks in route sequence. With rapid response to arriving delivery vehicles, fewer loading docks are required and more efficient use of truck space is possible.

Cimcorp’s Dream Factory solutions are revolutionizing tire production and distri-bution facilities worldwide. Using robotic technology for handling, storage and picking, our systems auto-mate the material flow from raw materials goods-in to the finished tire loading dock.

3. Curing

4. Testing

1. Raw material and component processing

5. Palletizing

6. Warehousing

7. Shipping

Markku Vesa, President, Cimcorp

With Dream Factory, we can ensure that you achieve the maximum possible throughput of high-quality tires.

2. Green tire processing

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TOTAL MATERIAL FLOW CONTROLProducing high-quality tires requires careful processing of raw materials and component management. This is where Cimcorp’s Dream Factory solution begins.

Efficient logisticsTire manufacturing requires intelligent management of internal logistics, attention to product quality and precise timing. Cimcorp’s material handling solution begins in the raw material and component processing area, where our WCS control system with gantry robots, ASRS or intelligent AGVs can take care of the handling requirements.

Control is keyAs in all areas of a tire-manufacturing plant, control of the material flow is key. By logging material batches, operators and processing times, Cimcorp’s WCS

control system provides total logistics management: • Completecomponentdatamanage- ment for the tire-building process•Productflowcontrolandintegration of the SCADA systems of process machines with the host system, such as SAP• In-ProcessVerification(IPV)to check that the right raw materials, components or products arrive at each processing station• Completetraceabilityof raw materials and components• Real-timeinventories• Consumptionforecasts• Reportsandalerts

Higher productivityRapidandefficienthandlingof raw materials and 100% component availability resultin higher throughput for the tire-building machines.

Lower inventoryWith improved information on raw material and component requirements and processing,manufacturers need lower stock levels and less space, which frees up capital for other uses.

Complete traceabilityCimcorp’s control systems provide comprehensive tracking and tracing informa-tion for each individual tire.

Customer benefits

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Esa ValtonenSales Manager, Cimcorp

Our WCS control system minimizes the green tire buffer and provides 100% availability of green tires at the curing presses.

www.cimcorp.com | 5


SPACE-EFFICIENT BUFFER OFGREEN TIRESProducing an optimal buffer of green tires between the building machines and the curing presses and handling it efficientlyiskeyformaximizingoutputatthelowestcost.

Automated processesAs part of our Dream Factory solution, we have developed several fully automat-ed systems for green tire processing: robots for unloading of the tire-building machines, transfer robots and electric monorailsystems(EMS)fortransporta-tion of tires from the building machines to the spraying area and gantry robots for green tire buffer storage. Our solu-tions also take care of the weighing and spraying processes, as well as related inspection functions.

Dynamic storageInourfullyautomatedhandlingsolution,storage is compact – partly due to higher storage density and partly because WCS control allows the buffer to be minimized.

Our buffer solution achieves a high storage capacity and can handle a wide range of SKUs(stock-keepingunits)simultaneous-ly. Green tires are automatically loaded, individually, onto a universal tire pallet and then picked up by the gantry robot. The dynamic storage system uses the floor space under the robot optimally.

FIFO controlCimcorp’s WCS control system – which takescareofbothmanufacturingexecu-tion(MES)andwarehousemanagement(WMS)functions–controlsthestorageand the flow between tire building and curing,maintainingtheFIFO(firstin,firstout)principle.Tiresarepickedtomeetcuring press product orders and WCS provides complete tracking of individual tires through the whole process.

total controlThe material flow is optimized, with data on every tire recorded at each stage ofthe production process.

improved qualityTire quality is improved by eliminating the manual handling of green tires.

more production spaceHigh-density storage and minimal buffer stocks allow more space for manufacturing.

Customer benefits

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Kari MiikkulainenSales Manager, Cimcorp

Gentle handling, precise spotting and bead-to-bead dimension stretching improve thequalityoffinishedtires.

www.cimcorp.com | 7

Maximum outputAs the throughput of the curing presses determines the ultimate production ca-pacity of the plant, keeping the presses closed is paramount. Cimcorp’s Dream Factory solution optimizes the flow into the presses and eliminates unnecessary waiting times.

Automatic loadingRobotsarethemostefficientwaytoloadthe curing presses, with linear transfer robots automatically collecting tires from the green tire buffer and depositing them onthepress-loadingtables.Inexistingfacilitieswherethereisinsufficientspacefor linear robots, intelligent AGVs may be used instead. Precise spotting and

bead-to-bead dimension stretching can be integrated into the loading sequence.

Free access The gantry robot systems are fast, totally accurate and – by running overhead – leave the factory layout uncluttered, ensuringexcellentaccesstothecuringpresses at all times.

Total controlAs in all the other processes, the system is controlled by our WCS, with flow control and tracking of the route of individual tires maintained throughout. Tires leaving the curing presses by trench conveyor have had their complete data, including the required parameters from the curing process, recorded.

3. Curing

KEEPING THE PRESSES CLOSEDCimcorp’s systems result in 100% tire availability at the curing pressestoensuremaximumpressutilization.Thisisachievedbyintegrating the buffer store and transfer systems under the control of WCS.

Higher throughput100% tire availability at the presses ensures higher throughput for the curing process.

improved qualityAccurate and gentle tire hand-ling,exactspottingandbead-to-bead dimension stretching improve curing results.

unrivalled accessOverhead gantry operation for the handling robots ensures an open plant layout, with clear access to the presses.

Customer benefits

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Tero PeltomäkiVice President, Operations, Cimcorp

You can add, remove or modify the number of SKUs at any time and the system takes care of the required changes fully automatically.

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4. Testing

FLEXIBLE BUFFERING AND SORTINGInthefinishingprocess,ourrobots’flexiblebufferingandsortingoperations allow continuous curing press unloading as well as changesintheproductionmix,whilemaintainingtotalcontrol.

Robotic sortationFrom the curing presses, cured tires are conveyed to the trimming and visual inspection stations and from there to the robotic handling area. Robots pick the tires, sort them and stack them, accord-ing to type, on the floor. When batches are ready for testing, the robots transfer them to the tire-testing process.

Dynamic storageThe space on the floor under the gantry robots is always used in the optimum way to suit current production. There are noinherentrestrictions,suchasfixedconveyor lines for each SKU or racking for storage. The robots can pick tires

individually or in stacks and store them directly on the floor. When the productionscheduleorproductmixchanges, the floor space can be used dynamically to accommodate different sizes and types of tires.

Precise controlCimcorp’s WCS controls the flow and storage, maintaining product tracking andtheFIFOprotocolthroughout.Tire inspection results are attached to each individual tire code. Based on the results,tiresarecategorizedintospecificquality groups, directed to further processes or rejected by the system.

improved efficiency100% tire availability at the testing machines enhances efficiency.

flexibility as production changesThe dynamic nature of robotic, floor-based storage affords flexibilitytoaccommodaterapid changes in production that reflect market demand.

fifo controlWith WCS in control of handling operations, tires are handledinstrictFIFOorder.

Customer benefits

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Jyrki AnttonenManager, Technology, Cimcorp

We can palletize all your products, whether you want them horizontally, vertically or in a rick-rack pattern.

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Higher efficiencyTireless and error-free auto-matic operation results in continuously high productivity.

improved qualityAutomatic handling, beingmore gentle than manual handling, ensures higher tire quality.

storage space savingsOptimal loading of pallets and cages results in better utiliza-tion of storage space, allowing more of the plant’s footprint to be used for production.

Customer benefitsRobotic loadingFully automated pallet and cage loading is an integral part of Cimcorp’s Dream Factory.Agantryrobotsortsfinishedtires arriving from the inspection area into stacksonthefloor.Tiresareidentifiedand stacked according to type and grade.Whentherearesufficienttiresof one type for a pallet load, the robot loads them onto a pallet or into cage.

Various load formats Tires can be loaded in three different ways. They can be stacked with tires positioned horizontally, loaded with each tire in a vertical position or palletized in arick-rackpattern.Eachtiretypehasitsownloadingprofile,sotherobotcanfilltheunitloadwithasmanytiresas possible for the SKU in question. The rick-rack pattern is the most space-efficientloadingformat.Cimcorp’ssystems create the optimal palletizing pattern for each tire type, based on a 3D model of the tire. WCS controls the palletizing process, again maintain-ing product tracking throughout.

5. Palletizing

VARIOUS LOAD FORMATSCimcorp offers systems for automatic palletization of finishedtires,whethertheyareloadedhorizontally,vertically or in a rick-rack pattern on pallets or in cages.

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Jarno HonkanenSales Project Manager, Cimcorp

Cimcorp’s WCS control system provides a rapid response and accurate delivery of your customers’ orders.


6. Warehousing

REAL-TIME INVENTORY UNDER WCS CONTROLThe chain of logistics control should not be broken once the tires reach the warehouse. Whether using automatic cranes or manual forklifts, storage can be fully managed by Cimcorp’s WCS.

Automated storageAsanexperiencedsystemsintegrator,Cimcorp can bring together all the elements of automated warehousing technology to create a seamless opera-tion, whether the warehouse is directly connected to the tire-manufacturing process or at a separate location. Pal-letized loads arrive and are transported by conveyor through a check station wheretheyareidentified.Loadsarethenconveyed to the crane aisles, picked up by automated stacker cranes and stored inpalletracking.Ifrequired,storagecanbe two pallets deep on each side oftheaisleforextrahighdensity.UnderWCS control, pallets are retrieved by the cranes automatically when required for order picking and conveyed to the de-palletizing and picking area. Automated warehousing is a mature technology and we have many systems in operation world-wide in a variety of industries – some over 40m tall. We can work with either conventional buildings or with ‘clad rack’ structures, in which the racking itself supports the walls and roof.

Manual warehousingChoosing a manual storage operation does not have to mean loss of control. RadioDataTerminals(RDTs),mountedon board the forklift trucks and linked to Cimcorp’s WCS, can be used to guide operators through the process to ensure that stock integrity and traceability are maintained at all times.

Whether you choose an automated or manual warehousing solution, the key when designing your warehouse is not only to consider the storage needs but also to ensure that the handling capacity provides a fast response to thenextstepsintheprocess–pickingand dispatch.

unbroken controlCimcorp’s WCS is a compre-hensive control solution that optimizes tire handling and storage through every step of production and distribution.

space savingsThe ASRS solutions provide great space savings in comparison to manually operated warehouses.

real-time inventoryWith automatic warehousing and our WCS control system, youbenefitfromreal-timeinventory.

Customer benefits

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Otso TinkalaSoftware Specialist, Cimcorp

Tire shipments and space-efficienttruckloads are automatically generated by the order-handling system.


error-free pickingRobotic order picking ensures rapid response to market needs at the lowest cost and with 100% accuracy, minimiz-ing the cost of returns and im-proving customer satisfaction.

transport savingsRapid order picking reduc-es delivery vehicle turnaround times and requires fewer ship-ping gates, trucks and trailers.

space savingsHigh pick rates avoid the need for loads to be pre-marshaled, requiring less space.

Customer benefits

7. Shipping

ERROR-FREE DELIVERIESThe speed and accuracy of Cimcorp’s systems for order picking and dispatch minimize truck turnaround times and reduce the number of vehicles and shipping gates required.

Rapid responseShipping is the direct link to the market, so response to demand has to be accurate and fast. Finished tires from production,possiblymixedwithfinishedgoods arriving from other group plants, must be picked and delivered according to customer orders and on time.

Accurate pickingCimcorp’sJITorderpickinganddispatchsystemssignificantlyimproveoverallefficiencyintheshippingareaviaatwo-stage process. Firstly, tires for orders to be delivered are retrieved from the warehouse, depalletized by a robot and stacked in the floor storage area ready for picking. Then, on advice of vehicle arrival, the robot picks the order with

100% accuracy and delivers it to the allocated output conveyor or to a palletizing robot, depending on the delivery mode.

Optimum sequenceTires are picked in reverse order to the drop sequence to facilitate the delivery process, should the vehicles have more than one destination. After order picking, the tires are labeled ready for loading into delivery vehicles. As always, the floor area under the robot is dynamically allocated for the different sizes and types of tire. WCS ensures control, tracking, data storage and communication with host systems throughout.

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PRODUCTION DATA MANAGEMENT FOR COMPLETE CONTROLPowerful softwareCimcorp’s WCS control system provides an unbroken chain of control formanufacturingexecution(MES)andwarehousemanagement(WMS)–fromindividual robot movements, through material flow to interfaces with host and other systems. With core software modules used in every project, stability and reliability are guaranteed. However, as each plant is unique, we use our considerableexperienceofsystemintegration in the tire industry to deliver tailored solutions.

Processes optimized Developedspecificallyforthetireindustry, WCS controls all automated equipment and takes care of key func-tions such as receiving product from upstream processes, routing of tires to the robots and sorting tires by SKU, whilemaintainingFIFO.Thesoftwarealso controls the storage operation, using floor areas dynamically to optimize use of space, and organizes process execution.Easy-to-usegraphicaluserinterfaces assist operators by showing the real-time status of the system, including inventory visibility, giving full controloverWIP(WorkInProcess).

Full tracking and tracingComprehensive data management for each step of manufacture and distribu-tion – recording information such as batch numbers, operators, weights, processing times and test results – ensures accurate product tracking at individual tire level and 100% trace-ability. WCS also uses this information forIn-ProcessVerification,ensuringthat the right raw materials or products are delivered to the processing and testing machines.

Our proven WCS software has been developed to manage fast-moving, real-time, robotic handling operations in order to optimize material flows and meet tight delivery deadlines.


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VERSATILEROBOTIC HANDLINGTECHNOLOGY



sales


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testingtrimming

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3. Curing

4. Testing


5. Palletizing

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7. Shipping

















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Our strengths


















uptime.




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