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LCIA

LCIA. Bram Kale European Engineering manager. OMRON Omron Europe B.V. PLC’s. Vision & ID systems. Human Machine Interface. Timers & Counters. Motion Control (OYMC). Sensors. Card-Readers. OMRON Industrial automation. Japanese multinational 35.000 employees 5.8 Billion in Euro

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LCIA

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  1. LCIA Bram Kale European Engineering manager . OMRON Omron Europe B.V

  2. PLC’s Vision & ID systems Human Machine Interface Timers & Counters Motion Control (OYMC) Sensors Card-Readers OMRONIndustrial automation • Japanese multinational • 35.000 employees • 5.8 Billion in Euro • Industrial automation products

  3. Engineering Process design Product design SMT automated production LCIA assembly Assembly Manual production

  4. LCIA Assembly Description LCIA – Low Cost Intelligent Automation is a system for effective manual production, where manual stages, simple control systems and clever tools are integrated to a flexible, productive and high quality method of assembly.

  5. LCIA assembly Productivity improvement Reduction of Quality problems Increase production Flexibility Focus points:

  6. 7 -Overproduction -Waiting time -Transportation -Processing -Inventory -Motion -Product defect 1. Consequent Elimination of Waste [Muda] 2. Synchronization of Chain of Processes LCIA assembly Drivers of the system Anchor in the line set up

  7. LCIA assembly Balance the strong points of the worker • Flexible • Intelligent • Accurate • Repetitive with those of the machine

  8. Basics of LCIA assembly Productivity Quality Flexibility • Flexible number of operators in line • One-piece flow, fixed # WIP • Standardized labor • Ergonomically sound • everything in a fixed place (5S) • LCIA solutions • Fool-proof (Poka-Yoke) solutions • Efficient work allocation • Teamwork • Paced to (stable) cycle time • Easy & not disturbing material replenishment from outside • Visual management • Flexible number of operators in line • Make many products in one line • Quick change over time • Easy to train operators • Standing style operations Standardized labor Paced to (stable) cycle time Standing style operations Fool-proof (Poka-Yoke) solutions

  9. LCIA effect Productivity Quality Flexibility CQM1 PLC assembly line: Cycle time reduction of 250%

  10. LCIA effect LED allways on Intensity Wrong color No illumination Flexibility Productivity Quality • From: • Manual visual check • Avg 63 customer complaints per year • Estimated >1000 defects per year • To • Low cost vision system • Zero defect & • Inspection time reduction • (20 sec)

  11. LCIA effect Productivity Quality Flexibility 35 different product in one line with change over time <30 sec.

  12. Design process • Line design very early in the product development process • Use Process FMEA to predict possible fault causes • Decide necessary tools based on FMEA level • Detailed Line Design and assembly • Test runs, measure designed cycle times, optimization

  13. Thank you for your attention

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