Automatic end of line buffer on AGV’s
Digital Manufacturing Vitoria Seating Barcelona 24th May 2019 Agenda
1 Faurecia Group. Faurecia Seating. Faurecia Vitoria
2 Context: Project & alternative solution
3 Buffer on AGV’s
4 People Vs Innovation, new technologies
5 Lessons Learn
2 Agenda
1 Faurecia Group
3 FAURECIA GROUP
As a global leader in automotive technology, Faurecia provides innovative solutions to automotive challenges within its four strategic businesses: Faurecia Seating, Faurecia Interiors, Faurecia Clarion Electronics and Faurecia Clean Mobility
4 FAURECIA GROUP
5 Agenda
1 Faurecia Seating
6 Faurecia Seating
#1 worldwide in mechanisms & seats structure #3 worldwide in complete seats
€7,1 billion Value-added sales 2017
44,800 employees
74 productionemployees sites
19 R&D and D&D Global standard frame platform Full JIT services and seat component centers leader offer: covers, foams, accessories Full range of high> performance Personalized through Smart Comfort mechanisms solutions 23 Advanced mechatronic systems Seat Electronics countries
7 Faurecia Seating: strong presence in all automotive regions
NORTH AMERICA EMEA 24% 56% 10 38 3 11 7,700 27,900
ASIA 16%
SOUTH 21 AMERICA 4 7,000 4% 5 1 2,200 Products sales Plants R&D centers Employees
8 Footprint seating| 74 plants
France Germany Poland Romania Caligny Neuburg Grojec Talmaciu Cercy la Tour Neuenstadt Jelcz Valcea Flers-en-Escrebieux UK Walbrzych³ Russia Magny-Vernois Banbury Czech Republic Saint Petersburg Montbéliard Spain Pisek Togliatti Nogent-sur- Pamplona Pilsen Vernisson Valladolid Slovakia Pulversheim Vigo Lozorno Rennes Vitoria-Gasteiz Trnava Sandouville Netherlands Villers la Montagne Sittard Portugal 2 Nelas Sao Joao de 1 1 2 5 Madeira² 2 2 USA 10 Vouzela 2 Cleveland 4 South Korea Cottondale 6 4 Yeongcheon Madison 1 1 2 1 15 Simpsonville Morocco Sterling Heights Kenitra 5 4 China Wentzville Sale Anting Mexico Tunisia Changchun San Luis Potosi² Ben Arous Iran Changshu Ramos Tehran Chengdu Puebla² India Guangzhou Chennai Nanjing 3 Manesar Pudong Pune Shanghai Sanand Brazil Shenyang Quatro Barras Tianjin 1 1 Porto Real Wuhan² Sao Jose dos Wuxi Pinhais Xiangyang Uruguay Yancheng San Jose Argentina Escobar 9 Complete seat offering | Excellence
Perceived Quality Components Best Complete Seat Program designed for optimal offering for Industrial Management Assembly (DFA) System Efficiency AND Seating Customization
The most innovative component portfolio designed with a Seating Complete Seat System System Modular & Flexible Mindset Performance Assembly Processes
Accessible Experts Accessible committed to deliver Experts highest Seating System Performance
Tier 2 management Digital Enterprise Launch Expertise
10 Complete seat - References
Audi Q7 BMW Mini Citroën Space Tourer Ford F-350 Cadillac CT6
11 Agenda
1 Faurecia Vitoria
12 Vitoria Key Figures
Mercedes Benz Facility & I-Park Faurecia Vitoria Faurecia Vitoria
150 HC
Direct Labour 120
Indirect Labour 30
Current JIT Conditions
Volume = 700 cars / day
Shift pattern: 3 shifts /day
JIT window = 4 hours
13 Vitoria Plant
New complete lay out :
Kitting
Picking
AGV’s components
The most current innovative final buffer using AGV for sequencing in Faurecia
14 Agenda
1 Faurecia Group. Faurecia Seating
2 Context: Project & alternative solution
15 Context: Project & alternative solution
Faurecia Vitoria, in their approach to industry 4.0 strategy, launched a big digital transformation in the last 2 years
Introduction 4 AGV • 2 for Kitting boxes
• 1 for Back rest components
• 1 for Cushion components
Kitting / picking
Automatic transfer • Beginning line box&unload kitting • End of line box
16 Context: Project & alternative solution
Mercedes Benz Vitoria planned to implement an aero conveyor instead of current train delivery system.
New approach to look for a warehouse management system with automated vehicles, specially designed to work in confined spaces, operating 24 hours a day thanks to loop battery charging stations
17 Agenda
1 Faurecia Group. Faurecia Seating
2 Context: Project & alternative solution
3 Buffer on AGV’s
18 Buffer on AGV’s
System: several main sub-process:
Inbound
Outbound Manual Robot + Stocker
Control system
19 Buffer on AGV’s
Sub-process Inbound:
Through a weightless handling system, workers transfer the car seat from the end of the line to the Trolley handled by an AGV. Video Inbound
After status seat check, delivers it to a buffer in a chaotic way => not in sequence. Video chaotic
20 Buffer on AGV’s
System: The system has managed to automate the whole loading system [and] storage seats sequencing in a warehouse at level zero, thereby facilitating the control system and backup if necessary
26 AGV in total operate the system.
AGV can rotate 360º on its own axis and is equipped with a lifting platform and a RFID Video system 21 Buffer on AGV’s
Sub-process Outbound: AGV´s pick car seat from the buffer in customer sequence, and deliver it to a presequence area (buffer to decouple inbound and outbound) that feeds the sequencing area.
All of that is synchronized with a predetermined sequence to ensure each seat goes to the correct place on the Mercedes’s train Video outbound
22 Buffer on AGV’s
Robot+Stocker: Loading robot picks the car seats one by one from AGV to load in stocker pallet
Stocker automatic line pallet to be delivered in sequence to conveyor customer assembly and finally to line fitting point.
All of that is synchronized to ensure each seat goes to the correct sequence of Mercedes Video
23 Agenda
1 Faurecia Group. Faurecia Seating
2 Context: Project & alternative solution
3 Buffer on AGV’s
4 People Vs Innovation, new technologies
24 People Vs Innovation
25 Agenda
1 Faurecia Group. Faurecia Seating
2 Context: Project & alternative solution
3 Buffer on AGV’s
4 People Vs Innovation, new technologies
5 Lessons Learn
26 Lessons Learn
“Very flexible system” that allows very quick layout improvements and capacity increase or decrease, key in a customer environment more and more flexible with volume changes.
Simplified Back-up mode management (direct access to all products) => Big advantage comparing to any other system (ASRS, traffic buffer, etc)
Capex management Optimization, Re-usable and able to transfer between plants & adjustable quantity of AGV depending of program phase
27