US-based Steeplechase Software, Inc., a leading PC-based control company, has been selected by Donnelly Corporation, the world“s largest producer of automotive mirror systems, for control of its auto…
US-based Steeplechase Software, Inc., a leading PC-based control company, has been selected by Donnelly Corporation, the world“s largest producer of automotive mirror systems, for control of its automated mirror assembly lines. Donnelly said Steeplechase“s award-winning software was selected based upon its power and high performance, and ability to meet Donnelly“s automation goals. Because of the ability of PC-based control to closely integrate with manufacturing Information Systems, Donnelly said it is able to offer its automotive customers a true “batch of one” for In-Line Vehicle Sequencing (ILVS). Side view mirrors are assembled according to specified colours and features, known as Just-In-Time (JIT) assembly, in the exact order in which they will be used by the automotive Body Manufacturing Assembly (BMA) plants. Previously, vendors relied upon inventories of batch colours to fill orders. According to Mike English, Program Manager for Donnelly, “Our primary goal in selecting Steeplechase was to automate the information flow – from the automotive manufacturer“s customer orders, to our plant scheduling system, JIT assemblies, through the material handling of totes for final automotive assembly. Without the automation of our assembly lines and enterprise-wide connectivity, we could not have achieved our zero error tolerance or rigid timeline goals.” The two-node automated Donnelly line manufactures right and left side view mirror assemblies for Ford Motor Company“s Taurus model. Installation of the new automated PC-based control line has significantly increased the daily output compared to older lines controlled by Programmable Logic Controllers (PLCs). Each workstation has a dedicated human-machine interface (HMI) running on a PC for easy operator access to schedules, build information, and most importantly diagnostics. “We cut the projected 5% downtime of the line in half – to 2.5%,” said Mark Werthman, Steeplechase Project Manager. “Built-in diagnostics help Donnelly to identify the cause of a fault, and help them get the line up and running in record time.” Donnelly“s side view mirror assembly consists of numerous components, such as an injection-moulded housing in a specified colour, heating unit, patented mirror, automatic or manual adjusting mechanisms, all held in a nest that travels along the line. Donnelly has the capability to produce sixty mirrors of different colours and options. A DVT Series 600 SmartImage Sensor system interfaces to Steeplechase and performs automatic identification and data capture, delivers tracking information and inventory control, and helps to ensure quality of the parts. The DVT unit plugs into Steeplechase for seamless integration, and visually tracks the progress of the build. A laser sensor on each pack station only allows mirrors that have passed inspection to be packed in a shipping tote.