From pilot stations

towards flexible

mass production lines

Huub Camp

May 10th, 2011

Confidential May 10th, 2011 2

Content

- Introduction

- Six levels of mechanization in a historical context

- Six levels of automation for new products

- A LEVEL 6 example

- How to make the difference in the future in Western Europe

Confidential May 10th, 2011 3

- 1980-1986 Technical University Eindhoven (Mechanical engineering)

- 1987-1994 Philips Lighting Eind. (Equipment & System Engineering)

(engineer , sr. engineer , project leader/architect)

- 1994-1995 Philips Lighting Turnhout (Mechanization department)

(group leader, architect, account manager)

- 1995-2000 Philips Lighting Terneuzen (Mechanization department)

(department manager + customer relation)

- 2000-2004 Assembleon Eind. (pick & place equipment ) (owned by Philips)

Program & BU manager feeding systems

- 2004-now Philips Lighting Turnhout : Global Technology Development

Mechanization

- 2004-2007 Progam manager DPL (digital projection lighting)

- 2007-2009 Program manager new business development LED/OLED

- 2009-2011 Program manager EXTERNAL business development

Confidential May 10th, 2011 4

Lighting

Healthcare

Consumer Lifestyle

Started in 1891 with the production of incandescent lamps

Confidential May 10th, 2011

PRODUCTIONPRODUCT DEVELOPMENT GTD MECHANIZATION

GTD MECHANIZATION

Link between Product Development and Production

Confidential May 10th, 2011 6

TurnhoutBelgium

AachenGermany

PilaPoland

BangpooThailand

ShanghaiChina

RoosendaalNetherlands

SurabayaIndonesia

EindhovenNetherlands

GTD MECHANIZATION

Global Network

Number of equipment and process FTE

Turnhout : 95 FTE

Roosendaal: 65 FTE

Aachen : 80 FTE

Pila : 40 FTE

Shanghai : 35 FTE

Others : 15 FTE

GLOBAL TECHNOLOGY DEVELOPMENT MECHANIZATION

Confidential May 10th, 2011 7

Six levels of mechanization in a historical context

Level 1 - maximum manual

- quality <->craftsmanship

Confidential May 10th, 2011 8

Six levels of mechanization in a historical context

Level 1 - maximum manual

- quality <->craftsmanship

Level 2 - some process tools/workstation

- quality <->craftsmanship

Philips glass factory

1916

Confidential May 10th, 2011 9

Six levels of mechanization in a historical context

Level 1 - maximum manual

- quality <->craftsmanship

Level 2 - some process tools/workstation

- quality <-> partly craftsmanship

Level 3 - coupled workstations

- quality<->partly craftsmanship

- handling manual

Philips 1920

Confidential May 10th, 2011 10

Six levels of mechanization in a historical context

Level 1 - maximum manual

- quality <->craftsmanship

Level 2 - some process tools/workstation

- quality <->partly craftsmanship

Level 3 - coupled workstations

- quality<->partly craftsmanship

- handling manual

Level 4 - first coupled machines

- quality<->process automated

- automated transport

Philips 1934

Confidential May 10th, 2011 11

Six levels of mechanization in a historical context

Level 1 - maximum manual

- quality <->craftsmanship

Level 2 - some process tools/workstation

- quality <->craftsmanship

Level 3 - coupled workstations

- quality<->craftsmanship

- handling manual

Level 4 - first coupled machines

- quality<->process automated

- automated transport

Level 5 - multi product type lines

- process automated + control (scada)

- optimized buffers

Weert :incandescent early 60 (speed 2000/hour)

70’s and 80’s speed increases up to 5000/hour

Roosendaal: TL (speed HOR 2000) late 60’s

70’s and 80’s HOR 3000 and HOR 6000

90’s speed increases to 7200/hour

Confidential May 10th, 2011 12

Six levels of mechanization in a historical context

Level 1 - maximum manual

- quality <->craftsmanship

Level 2 - some process tools/workstation

- quality <->craftsmanship

Level 3 - coupled workstations

- quality<->partly craftsmanship

- handling manual

Level 4 - first coupled machines

- quality<->process automated

- automated transport

Level 5 - multi product type lines

- process automated + control (scada)

- optimized buffers

Level 6 - flexible lines (many product types)

- control 6 sigma (Scada +MES+ERP)

- Central Control Room (lean)

Confidential May 10th, 2011 13

Six levels of automation for new products

Level 1 - maximum manual

- quality <->craftsmanship

Level 2 - some process tools/workstation

- quality <->partly craftsmanship

Level 3 - coupled workstations

- quality<->partly craftsmanship

- handling manual

Level 4 - first coupled machines

- quality<->process automated

- automated transport

Level 5 - multi product type lines

- process automated + control (scada)

- optimized buffers

Level 6 - flexible lines (many product types)

- control 6 sigma (scada +MES)

- Central Control Room (lean)

Product developer makes first of

a kind

GTDM develops first process

tools and process for proto serie

GTDM develops 6 sigma robust

process on pilot equipment

GTDM designs/build a low speed

line.

GTDM designs/build a high speed

line.

Line improvements + additional

product types

Huub Camp

May 10th, 2011

Central Control Room

A LEVEL 6 example

Confidential May 10th, 2011 15

Turnhout

Eindhoven

15

Innovative Display Solution Provider

Confidential

Road MapRoad Map

4Q02 1Q03 2Q03 3Q03 4Q03

High

Main

Value

DP757

• 6.6lbs, 2100L(Min 1680L)

• 0.7” XGA/12/DDR DMD• 250W 1.35mm lamp

• MP: 1Q/03

DP737

• 3lbs, 1300L(Min 1020L)

• 0.7” XGA/12/DDR DMD• Non-telecentric Zoom Lens

• 150W 1.3mm lamp PFC or 180W E19 PFC

DP821

• 4.2lbs, 1000L(Min 800L)• 0.55” SVGA/12/DDR DMD• DDP2000

• Fixed Lens/Zoom 85W/s•150W 1.3mm 52x56mm lamp

• MP: 3Q/03•UHP 200WE19 Laptop

DP725

• 2lbs, 1000L(Min 800L)

• 0.7” XGA/12//DDR DMD• Zesis S2 Engine 85W/s

• 132W 1.0mm lamp• MP: 2Q/03

DP820

• 4.2lbs, 1000L(Min 800L)• 0.55” SVGA/12/DDR DMD

• DDP1000• Fixed Lens/Zoom 85W/s

•150W 1.3mm 52x56mm lamp• MP: 1Q/03

•UHP200WE19 Laptop

DP866

• 7lbs, FSC / SCR Engine

• 2200 (min. 2000)/ 3000L(min 2400L)• 0.7” XGA 12D DDR / LVDS DMD

•UHP 250W 1.3mm /250W 1.0mm lamp• MP: 4Q 2003/ 1Q 2004

DP830

• 3lbs, 1600L (min. 1300L)

• 0.7” XGA/12D/DDR DMD• Zoom Lens

• DDP2000•UHP 200W 1.0mm E19 PFC Dim

• MP: 4Q/03

DP822

• 4.2lbs, 1300L(Min 1050L)• 0.55” SVGA/12/DDR DMD

• DDP2000• Fixed Lens/Zoom 85W/s• 200W 1.0mm E19 Laptop

• MP: 4Q/03

Confidential May 10th, 2011ScaleUnitName

Tom Van de Perre

DateVersion

1/1

A B

C2 C1

D

GJK

H

I

2.52.5

Productparameters for

UHP shaped bulbs

mm

13 mei '03V 1.3

Scale

10/1

E

L

KInwendige diameter buis

IDelta L (Verschuiving inw / uitw)

GMinimum inwendige +

ERIK (stRaal Inwendige Kontour)

Wanddikte + & -

AUitwendige diameter

LLengte produkt

JUitwendige diameter buis

HDx max. (Verschil onder / boven)

F125 maat

DKoord bol

BInwendige diameter

C1/2

5.0

F

DMAIC

GEOMETRIEMETING POSITIE 12 MET VISION 2 CAMERA 2

M1: (A – C) = AFWIJKING MIDDEN MO-BAND T.O.V. MIDDEN KLEMVEER ( kant klemveer ).

M2: (A – D) = AFWIJKING MIDDEN MO-BAND T.O.V. MIDDEN KLEMVEER (kant elektrode ).

Met M1 en M2 kan men de symmetrie en scheefstand van de Mo-band berekenen.

M3: (D – F) = AFWIJKING MIDDEN BALK T.O.V. MIDDEN MO-BAND (kant mo-band).

M4: (D – G) = AFWIJKING MIDDEN BALK T.O.V. MIDDEN MO-BAND (kant elektrodekop).

Met M3 en M4 kan men de symmetrie en scheefstand van de elektrode berekenen.

M5: (B – E) = LENGTE MO-BAND

M6: (E – H) = UITSTEEKLENGTE ELEKTRODE

M7: (I – J) = DIKTE ELEKTRODEKOP

M8: (D – H) = AFWIJKING MIDDEN VAN DE PUNT VAN DE ELEKTRODEKOP T.O.V. MIDDEN MO-BAND.

M9: (K – E) = AFSTAND VAN ZUIGER TOT ONDERKANT MO-BAND

M10: (K – H) = AFSTAND VAN ZUIGER TOT EINDE ELEKTRODEKOP

GEOMETRIEMETING POSITIE 7 MET VISION 2 CAMERA 1

MA: (L – N) = AFSTAND VAN ZUIGER TOT ONDERKANT MO-BAND MB : (L – M) = AFSTAND VAN ZUIGER TOT BOVENKANT MO-BAND

H

Zuig

er

A

E

F

B

G

C

D

I

K

J

Zuig

er

M

L

N

ScaleUnitName

Tom Van de Perre

DateVersion

1/1

A B

C2 C1

D

GJK

H

I

2.52.5

Productparameters for

UHP shaped bulbs

mm

13 mei '03V 1.3

Scale

10/1

E

L

KInwendige diameter buis

IDelta L (Verschuiving inw / uitw)

GMinimum inwendige +

ERIK (stRaal Inwendige Kontour)

Wanddikte + & -

AUitwendige diameter

LLengte produkt

JUitwendige diameter buis

HDx max. (Verschil onder / boven)

F125 maat

DKoord bol

BInwendige diameter

C1/2

5.0

F

GEOMETRIEMETING POSITIE 12 MET VISION 2 CAMERA 2

M1: (A – C) = AFWIJKING MIDDEN MO-BAND T.O.V. MIDDEN KLEMVEER ( kant klemveer ).

M2: (A – D) = AFWIJKING MIDDEN MO-BAND T.O.V. MIDDEN KLEMVEER (kant elektrode ).

Met M1 en M2 kan men de symmetrie en scheefstand van de Mo-band berekenen.

M3: (D – F) = AFWIJKING MIDDEN BALK T.O.V. MIDDEN MO-BAND (kant mo-band).

M4: (D – G) = AFWIJKING MIDDEN BALK T.O.V. MIDDEN MO-BAND (kant elektrodekop).

Met M3 en M4 kan men de symmetrie en scheefstand van de elektrode berekenen.

M5: (B – E) = LENGTE MO-BAND

M6: (E – H) = UITSTEEKLENGTE ELEKTRODE

M7: (I – J) = DIKTE ELEKTRODEKOP

M8: (D – H) = AFWIJKING MIDDEN VAN DE PUNT VAN DE ELEKTRODEKOP T.O.V. MIDDEN MO-BAND.

M9: (K – E) = AFSTAND VAN ZUIGER TOT ONDERKANT MO-BAND

M10: (K – H) = AFSTAND VAN ZUIGER TOT EINDE ELEKTRODEKOP

GEOMETRIEMETING POSITIE 7 MET VISION 2 CAMERA 1

MA: (L – N) = AFSTAND VAN ZUIGER TOT ONDERKANT MO-BAND MB : (L – M) = AFSTAND VAN ZUIGER TOT BOVENKANT MO-BAND

H

Zuig

er

A

E

F

B

G

C

D

I

K

J

Zuig

er

M

L

N

GEOMETRIEMETING POSITIE 12 MET VISION 2 CAMERA 2

M1: (A – C) = AFWIJKING MIDDEN MO-BAND T.O.V. MIDDEN KLEMVEER ( kant klemveer ).

M2: (A – D) = AFWIJKING MIDDEN MO-BAND T.O.V. MIDDEN KLEMVEER (kant elektrode ).

Met M1 en M2 kan men de symmetrie en scheefstand van de Mo-band berekenen.

M3: (D – F) = AFWIJKING MIDDEN BALK T.O.V. MIDDEN MO-BAND (kant mo-band).

M4: (D – G) = AFWIJKING MIDDEN BALK T.O.V. MIDDEN MO-BAND (kant elektrodekop).

Met M3 en M4 kan men de symmetrie en scheefstand van de elektrode berekenen.

M5: (B – E) = LENGTE MO-BAND

M6: (E – H) = UITSTEEKLENGTE ELEKTRODE

M7: (I – J) = DIKTE ELEKTRODEKOP

M8: (D – H) = AFWIJKING MIDDEN VAN DE PUNT VAN DE ELEKTRODEKOP T.O.V. MIDDEN MO-BAND.

M9: (K – E) = AFSTAND VAN ZUIGER TOT ONDERKANT MO-BAND

M10: (K – H) = AFSTAND VAN ZUIGER TOT EINDE ELEKTRODEKOP

GEOMETRIEMETING POSITIE 7 MET VISION 2 CAMERA 1

MA: (L – N) = AFSTAND VAN ZUIGER TOT ONDERKANT MO-BAND MB : (L – M) = AFSTAND VAN ZUIGER TOT BOVENKANT MO-BAND

H

Zuiger

A

E

F

B

G

C

D

I

K

J

Zuiger

M

L

N

16

DPL Burner production

+/- 50 Burner types

+/- 200+ Lamp types

Main goal : 8FTE 4FTE

Confidential May 10th, 2011 17

Q 1 2007 Q 1 2009

BP 2007-2010 Lean focus

Pre MEDIC

Main goal : 8FTE 4FTE

Confidential May 10th, 2011

18

control room

Design of control room

MEDIC

Machine

Visuele

operationSituation

Product

adjustmentsProcess

progressInspection

Eyes on the linecoupling with

machine controlManuals

Visualisation

proces

WHat

How

Confidential May 10th, 2011

Way of working

19

Concept

Product co-

development

Research

Feasibility

studies

Concept creation

Consulting

Lean solutions

Industrial

Efficiency

Specification

Industrial Setup

Manufacturing

process

development

Design for Six

Sigma

Design for

manufacturing

Prototyping

studies

Concept freeze

Engineering

Mechanical,

electrical and

software design

FEM analysis

System

integration

Project

management

CE - Safety

Ergonomics

Realization

Global sourcing

Assembly

Start & ramp up

Training

Repeats

Service

Product range &

capacity

extension

Productivity

improvement

Spare parts

management

Relocation

Industrial

Efficiency

Industrial Quality

GTD MECHANIZATION TURNHOUT

Confidential May 10th, 2011

20

MEDIC

• Fixed way of working

• Only essential controls

• Robust

• Simple/friendly to operate

CCR

• Flexible

• Maximal control

• Low cost testing

• NO production disturbance

Pilot CCR

Confidential May 10th, 2011

21

MEDIC

Definine and discripe the CCR hardware

Rand

apparatuur

Machine

besturing

Machine

besturingCamera Camera

Central Control

Room

Rand

apparatuur

Fabrieksnetwerk

Machine 1 Machine X

Control

server

Data

server

Image

server

Confidential May 10th, 2011

22

MEDIC

Implementation of the CCR

Central location near the line

Proces visualisation

Document pc

Machine control

Camera system

Confidential May 10th, 2011 23

Line Output Efficiency

50%

55%

60%

65%

70%

75%

80%

85%

90%

95%

100%

jan feb mrt apr mei jun jul aug sep okt nov dec

Maand

LOE

PRE

CCR

PILOT

CCR

IMPLEMENTATIE / DOCUMENTATIE

CCRCCR

Secondary Metrics

Waste

0%

2%

4%

6%

8%

10%

12%

14%

jan feb mrt apr mei jun jul aug sep okt nov dec

Maand

Was

te

PRE

CCR

PILOT

CCR

IMPLEMENTATIE / DOCUMENTATIE

CCRCCR

MEDIC

Confidential May 10th, 2011

Roles and responsibilities

123

• Escalation model out of control

– On 1 A4

DMAIC

Confidential May 10th, 2011

Addition to the Central Control Room

Visualization out of controls

Last 24 hours

Real-time Visualization on critical product parameters

DMAIC

25

Confidential May 10th, 2011

Breakthrough- and Continuous Improvement

Complementary to Each Other …

DMAIC

Learning and future

• SMED

• Machine OCAP Line OCAP

• Continuous operator engagement

External CONQ from

decreased

(2008 2009)

Prevented internal

CONQ

decreased

26

Confidential May 10th, 2011

How to make the difference in the future in

Western Europe

Glass processing

Micro dosing & small parts handling

Coatings

Light measurement

Vision systems

Micro welding

Glass-metal joining

Organic sources (OLED)

Information systems

Vacuum & Gas Technology

Mechatronics

Laser processing

UNIQUE GTDM CORE COMPETENCES

Positioning

Turn-key equipment

Heat management

Level 6 - flexible lines (many product types)

- control 6 sigma (scada +MES)

- Central Control Room (lean)

Close

cooperation

product

development

a learning

flexible

production

Process &

Equipment

development