Collins & Aikman, a leading Tier One automotive supplier, provides carpet sets to several major automotive manufacturers. These carpet sets, manufactured in three facilities, are made up of high quality carpet material and as many as four vinyl wear pads, added to increase the durability of the carpet sets.

Each of these sets is available in carefully selected colours with all elements, carpet and padding, matching detailed customer specifications. Recently Collins & Aikman, as part of its continuing quality improvement program, resolved to migrate the colour matching process from a manual to a fully automated process. The benefits of the process enhancement were to assure colour match quality from sample to sample, and to eliminate mistakes in colour matching due to human error.

After evaluating candidate solutions from other sensor companies, C&A came to Balluff. C&A had determined that colour sensors using fiber optic technology would fail due to inadequate separation of sensor lenses. Contrast sensors would also fail due to their inability to read colours off the carpet texture. One of the major problems in reading true carpet colour is, due to handling, the nap or pile can lay differently from one piece of carpet to the next, changing its perceived colour.

Balluff, a recognized leader in photoelectric colour recognition, went to work on the problem under the direction of C&A's Process Engineer Ted Manning. Roger Altendorf, Balluff's photoelectric sensor specialist went on-site to analyze the situation. "The trick in this application was to accurately read and match colour from two completely different materials. Different textures, materials, and nap angles dramatically complicated the problem, with the carpet material tending to display variable hue."

After evaluating a number of possible sensors and process solutions, the Balluff team came up with the answer -- using the Balluff BFS 26K colour sensor as a basis for the final colour matching process. Up to four Balluff sensors read the vinyl pads and two more read the carpet. The BFS 26K carpet sensors are programmed to recognize the carpet colour regardless of nap/pile orientation. The full-colour sensor has three programmable outputs which give it sufficient flexibility to be set up for go/no go for all the colour variations Collins & Aikman required.

Solid fixturing is key for any colour matching application. The carpet must be read at precisely the right angle and precisely the right distance. Set up distance was not as critical on the vinyl wear pad colour match, but a specific sensing angle was still needed to correctly read all the colours. The other key solution factor was that all elements in the process -- sensors, carpet, and pads -- had to be absolutely still for a split second. The Collins & Aikman team recognized this and devoted considerable effort to provide solid, positive fixtures for the Balluff sensors.

Collins & Aikman's Ted Manning comments, "Our automotive customers have absolute standards when it comes to colour match on these carpet pieces. Balluff has helped us substantially increase our yields of perfect carpet sets, while simultaneously raising our productivity and lowering our scrap rate."

The success of Balluff's accurate colour matching solution led to a second application for the BSF 26K sensors. Collins & Aikman uses a water jet cutter to prepare the finished carpet assemblies for correct installation in specific vehicles. Two BFS 26K sensors are now used in a final process check to ensure efficient production by making sure that only carpet sets that meet C&A's total quality parts criteria are cut for final installation.
Says Manning, "Quality and productivity is the name of the game when it comes to the automotive industry. Balluff gave us the means of simultaneously increasing our quality and our productivity to more than meet the requirements of our customers when it came to this particular production process."

Balluff Canada
 

In addition to the challenges of meeting industry noise regulations, the owner wanted to provide a safe and comfortable working environment for his employees. At the same time, the forklift operators needed easy access to the dumping area, without heavy doors to slow them down.

The Shaver team was called in to assess the situation, and within days, they had designed a custom power roll-up door that solved all of the problems.

Shaver redesigned a standard door by using special noise abatement material. The press shop owner was satisfied with Shaver's solution. Now, the employees are protected from the dangers of excessive noise, and the forklift operators can move quickly through the doors to get their job done.

Shaver Industries  

An automotive components and stamping supplier approached Global ET to help create an error proofing and data collection system for a transmission transfer case marriage subassembly line.

The supplier received a new project from Magna, who was responsible for attaching the transfer case to the transmission for the V6 and V8 DCX 300C transmissions. It was decided that the assembly of the transmission/transfer case should be offsite in a Just-in-Time delivery plant to reduce final assembly cycle time.

They selected Global ET to find the best, most cost effective and practical way to define and create an error proofing and data collection system. Working with Global ET allowed them to pull in an expertise it lacked inside the company - computer programming, software and electrical engineering.

Global ET, a supplier of integrated electronic solutions for data collection, analysis and error proofing, recommended using its SIMSigma solution to help Magna adhere to QS 9000 and Six Sigma quality requirements. SIMSigma is a turnkey electronic data collection and error proofing solution that enables manufacturers to measure, analyze, improve and control assembly and manufacturing processes on the plant floor.

Global ET Solution

Global ET worked with the components supplier and Magna to define system requirements and to implement a SIMSigma solution in a single station assembly line tailored to their specific needs. Global ET adhered to a very aggressive deadline, helped all parties stay focused on the project-scope, and developed a repeatable and reliable solution for the sub-assembly.

Global ET developed parallel build-up systems, allowing the Tier-1 to build two parts at a time. The system, located in a distribution warehouse, consists of computers, flat panel displays, network equipment, SIMSigma software, torque controllers, pick detectors, bar code scanners, two 3'x5' foot build-up tables and racks for stacking the parts.

Global ET incorporated specific work instructions from the OEM and created a system to control the process. The instructions were documented into an electronic format, along with graphics to make the process simple to follow and understand. The system incorporates impressive visual feedback with colour-coded computer graphics and photos to help guide the operator through the assembly process. When the operation is done correctly, the item on the screen turns green. If it is done incorrectly, it turns red.

Once the operator completes the assembly, it is put on a metal rack. Once the metal racks are filled, they are stacked on a forklift, put on a truck and driven to the final assembly line at the OEM facility.

This SIMSigma solution incorporates error proofing, data collection, reporting and statistical process control charting. This output is used to analyze and evaluate the manufacturing process.

Traceability is inherent in the system since it includes a bar coding system and other electronic devices. With SIMSigma, manufacturers can sort data by build history, VIN number, date built and sub-assembly line.

Result

The SIMSigma solution saves time and money on the final assembly line for DCX. Since the parts take five minutes to build, it is a significant time savings. Operators at the DCX plant have to pick just one part off the shelf and put it on the car. The increased efficiency resulting from off-site sub-assembly and SIMSigma error proofing has allowed the OEM to streamline its operation.

Even though Global ET was brought into the project very late, the program management disciples used by Global ET kept the project on time and exceeded all expectations, including those of DCX. The SIMSigma system proved to be robust, intuitive and easy to use.

Magna hopes to utilize the same type of SIMSigma solution for future assembly operations that are moved off-site to a Just-in-Time plant to relieve final assembly cycle time.
Without an error proofing system such as SIMSigma, there is more pressure on operators to not make human errors and follow work instructions. By implementing the SIMSigma solution, Magna could automate and control a very labour intensive process and make it easier for the operators to perform their duties.

It also gives both DVX and Magna the assurance that parts are built correctly. The error-proofing system helps save on warranty costs when only good parts are allowed to leave the plant. Warranty costs initially occurred by OEMs are often passed on to Tier-1 module suppliers and Tier-2 subcomponent manufacturers.

Global ET

Canadian Industrial Equipment News December 2005

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