(Đồ án hcmute) implementation deployment of an interlocking system to control process robustness for schneider electric manufacturing vietnam

MINISTRY OF EDUCATION AND TRAINING HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY FOR HIGH QUALITY TRAINING GRADUATION PROJECT MECHATRONICS ENGINEERING IMPLEMENTATION & DEPLOYMENT OF AN INTERLOCKING SYSTEM TO CONTROL PROCESS ROBUSTNESS FOR SCHNEIDER ELECTRIC MANUFACTRING VIETNAM ADVISOR: DR DANG TRI DUNG STUDENT: AN THANH TUNG SKL009893 Ho Chi Minh city, August 2022 HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY OF HIGH-QUALITY TRAINING GRADUATION PROJECT IMPLEMENTATION & DEPLOYMENT OF AN INTERLOCKING SYSTEM TO CONTROL PROCESS ROBUSTNESS FOR SCHNEIDER ELECTRIC MANUFACTURING VIETNAM Student Name: AN THANH TÙNG Student ID: 18142073 Major: MECHATRONICS ENGINEERING Advisor: ĐẶNG TRÍ DŨNG, PhD Ho Chi Minh City, August 2022 HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY OF HIGH-QUALITY TRAINING GRADUATION PROJECT IMPLEMENTATION & DEPLOYMENT OF AN INTERLOCKING SYSTEM TO CONTROL PROCESS ROBUSTNESS FOR SCHNEIDER ELECTRIC MANUFACTURING VIETNAM Student Name: AN THANH TÙNG Student ID: 18142073 Major: MECHATRONICS ENGINEERING Advisor: ĐẶNG TRÍ DŨNG, PhD Ho Chi Minh City, August 2022 i THE SOCIALIST REPUBLIC OF VIETNAM Independence – Freedom– Happiness -Ho Chi Minh City, August 31st, 2022 GRADUATION PROJECT ASSIGNMENT Student name: An Thanh Tung Student ID: 18142073 Major: Mechatronics in Engineering Class: 18146CLA2 Advisor: Dang Tri Dung, PhD Phone number: 0969810740 Date of assignment: 07/09/2022 Date of submission: 18/02/2023 Project title: IMPLEMENTATION & DEPLOYMENT OF AN INTERLOCKING SYSTEM TO CONTROL PROCESS ROBUSTNESS FOR SCHNEIDER ELECTRIC MANUFACTURING VIETNAM USING WINDOWS FORM APPLICATION COMMUNICATION WITH PLC M221 Initial materials provided by the advisor: Plant database (Work orders, quantity, schedule) Product Database (Product references, label templates, process flow diagrams) Using Visual Studio Windows Form Application Using Microsoft SQL Server Software Using EcoStruxure Machine Expert – Basic Software Content of the project: Build label database for the using references Create UI using the windows form application Modify the PLC program on usage devices suitable with the new UI Trial Run → Debug → Training → Live Run Final product: Windows Form Application is used for managing manufacturing activities Improve the process of product references to prevent bypass during operation time Create historical data for each product for easy tracking Compilation thesis report ii THE SOCIALIST REPUBLIC OF VIETNAM Independence – Freedom– Happiness -Ho Chi Minh City, August 31st, 2022 ADVISOR’S EVALUATION SHEET Student name: An Thanh Tung Student’s ID: 18142073 Major: Mechatronics in Engineering Project title: IMPLEMENTATION & DEPLOYMENT OF AN INTERLOCKING SYSTEM TO CONTROL PROCESS ROBUSTNESS FOR SCHNEIDER ELECTRIC MANUFACTURING VIETNAM USING WINDOWS FORM APPLICATION COMMUNICATION WITH PLC M221 Advisor: Dang Tri Dung, PhD EVALUATION Content of the project Strengths Weaknesses Approval for oral defense? Overall evaluate Score: …….……….in words: ) Ho Chi Minh City, Day , Month , 2023 REVIEWER (Sign with full name) iii THE SOCIALIST REPUBLIC OF VIETNAM Independence – Freedom– Happiness -Ho Chi Minh City, August 31st, 2022 PRE-DEFENSE EVALUATION SHEET Student name: An Thanh Tung Student’s ID: 18142073 Major: Mechatronics in Engineering Project title: IMPLEMENTATION & DEPLOYMENT OF AN INTERLOCKING SYSTEM TO CONTROL PROCESS ROBUSTNESS FOR SCHNEIDER ELECTRIC MANUFACTURING VIETNAM USING WINDOWS FORM APPLICATION COMMUNICATION WITH PLC M221 Name of Reviewer: Tran Thuy Uyen Phuong PhD EVALUATION Content of the project Strengths Weaknesses Approval for oral defense? Overall evaluate Score: …….……….in words: ) Ho Chi Minh City, Day , Month , 2023 REVIEWER (Sign with full name) iv ACKNOWLEDGEMENT First of all, I would like to express my deep gratitude to my advisor, Dr Dang Tri Dung, who guided me throughout the process of writing my project, for his insights and useful advice His extensive knowledge, willingness, and commitment have truly inspired me to keep learning with all my passion Although my topic is not too related to your expertise, you can still give me advice and direction in the project process as well as corrections and suggestions for my report Secondly, I would like to express my deep gratitude to the HCMC University of Technology and Education teachers for their dedication to imparting solid professional knowledge to students, which has helped me finish this project This project is a consolidation of my four-year knowledge gained from courses delivered by dedicated faculty In addition, I would like to especially thank the Schneider Electric team for their support during the project, both in terms of hardware and software, and the necessary equipment for the smooth operation of the system The Interlocking system is the result of the cooperation of all departments of the company, notwithstanding the contributions from the operators, who directly work with equipment that can come up with common failures mode v ABSTRACT Schneider Electric Manufacturing Vietnam is an expert in manufacturing switches and sockets with over 120 production lines but mostly are using manual process In recent years, SEMV has received many negative feedbacks from customers about (Product’s failed functions, missing components, not fully packaged, etc.) Despite the company has released OWS (Operation Work Standard) or using tester at each station to prevent error However, it is not the optimal way to control these failure modes Faced with the above problems, we discussed and found a solution that guides the workers’ operation and ensures that the processes are executed sequentially and cannot be skipped - the Interlocking System This system will combine with the current auto label printing system – Traceability- which will automatically generate a QR label The goals of this system should include upgrades of current hardware (upgrading QC testing machine, suitable hardware installation), data acquisition (product historical data, the condition of each product, tracing back the source of errors, production order), and compatibility (application for communication between hardware and database, general application platform to be applied to multiple production lines, establish communication between hardware and database) After a trial run and evaluation period, the system proved to be accurate, efficient, and coherent At the same time, create trust from customers and enhance SEMV's reputation However, this system remains some open points: lack of small components during assembly that cannot be detected by the testers, cannot detect the included accessories due to the error of the scale, increased cycle time, and still quite new to the workers resulting in them not adapting to the system By accepting that all failure modes cannot be controlled, this system has successfully reduced the RPN score and cycle time, fixed many of the early problems, and allowed live runs We are heading to apply for more lines & come up with new solutions to further improve this system Keywords: Manual process, Interlocking system, PLC, historical data, QR label, compatibility, control failure mode, skip processes, RPN score, cycle time vi TABLE OF CONTENT ACKNOWLEDGEMENT v ABSTRACT vi LIST OF TABLES x LIST OF FIGURES xi Chapter : INTRODUCTION 1.1 Project background & Problem Statement 1.2 Solution for the current situation of SEMV 1.3 Objective and Research Method 1.3.1 Objective 1.3.2 Approach Method 1.3.3 Implement Method 1.4 Scope and Limitations 1.4.1 Scope of the project 1.4.2 Limitations Chapter : LITERATURE REVIEW 2.1 Theory of Interlocking 2.2 Application Analysis 2.2.1 Windows Form Application Programming 2.2.2 Modbus TCP/IP protocol 10 2.2.3 RS-232 communication [15] 13 2.2.4 SQL Server Management Studio (SSMS) 15 2.2.5 EcoStruxure Machine Expert Basic [19] 18 2.3 Currently process control application in SEMV 20 2.3.1 Iconic Packing Application 20 2.3.2 Chameleon Packing 21 2.3.3 Poka-Yoke Packaging 22 2.4 Failure mode and effects analysis (FMEA) [21] 24 2.5 Ergonomic workbench systems for industrial & commercial use 27 Chapter : DESIGN AND IMPLEMENTATION 30 3.1 System Overall Block diagram 30 3.1.1 Block listing 30 vii 3.1.2 Block Diagram 32 3.1.3 System Operational Description 33 3.2 Layout design 33 3.3 Electrical Design 36 3.3.1 Block listing 36 3.3.2 Electrical block diagram 37 3.3.3 Electrical cabinet design 37 3.4 Printing Application Design 38 3.4.1 Overall architecture application 38 3.4.2 Database management 39 3.4.3 Devices Configuration 42 3.4.4 Printing Operational 45 3.4.5 Printing Application Interface 45 3.4.6 Control Design 49 3.5 Testing Application Design 50 3.5.1 Overall Architecture Application 50 3.5.2 Database Management 52 3.5.3 Devices Configuration 54 3.5.4 Testing Operational 57 3.5.5 Testing Application Interface 57 3.5.6 Control Design 60 3.6 Packing station 61 3.6.1 Overall Architecture Application 61 3.6.2 Database Management 62 3.6.3 Devices Configuration 64 3.6.4 Packing Operational 66 3.6.5 Packing Application Interface 66 3.6.6 Control Design 70 3.7 Layout Implementation 72 3.7.1 Workstation implementation 72 3.7.2 Electric implementation 73 Chapter : EXPERIMENTAL, ANALYSIS, SUMMARY RESULTS 74 viii Chapter : EXPERIMENTAL, ANALYSIS, SUMMARY RESULTS 4.1 Design Experiments 4.1.1 Qualitative Statements It needs to prevent bypass for the whole manufacturing process (40%) It needs to prevent missing big parts (20%) It needs to prevent missing products package (20%) It should not heavy impact on product cycle time (10%) Reduce change over time (10%) 4.1.2 List metrics Table 10: Establish metrics and units No Needs M1 M2 Metrics Imp Unit Defect rate Times 1,2,3 Risk priority number Band score M3 1,2,3 Occurrence of failure mode Band score M4 1,2,3 Detection of failure mode Band score M5 Coe-Efficiency (KE) % M6 Cycle time Minute M7 Preventive maintenance steps step M8 Preventive maintenance time minute *Imp stands for Important Rate (Using a scale of 1=little important to 5=very important) 74 Table 11: Link metrics to needs Need METRICS M1 M2 M3 M4 M5 M6 M7 M8 N1 X X X X N2 X X X N3 X X X N4 X N5 O O O X - Indirect measure: the quantity to be measured is not measured directly but another related parameter is measured and inference is drawn from there O – Direct measure: the quantity to be measured is determined directly by measurement tools such as a caliper, micrometer, etc 4.1.3 Propose specification Table 12: Assign marginal and ideal values SPECIFICATIONS OF PRODUCT No Specification name Imp Unit Ideal value Marginal value Group Defect rate time BASIC Risk priority number of actions Score Depend Depend BASIC Occurrence of failure mode Score BASIC Detection of failure mode Score - BASIC KE Impact % No Impact BASIC Cycle time second 2.5 BASIC Preventive maintenance time minute 40 50 BASIC Preventive maintenance step step - BASIC 75 BASIC is all static measurable metrics, and functions that a typical product should have ADVANCE is all static measurable metrics, functions that improve the product performance and cost by more than 10% ADDITIONAL is all static measurable metrics, functions that add value to the product but not making the product cost higher than 10% 4.1.4 Experiment Method Table 13: Table methods of experiments METHODS OF EXPERIMENT Specification name Unit Sampling Types of Test Static Defect Rate Time The Risk priority number of actions Score Occurrence of failure mode Score Detection of failure mode Score KE month 1 Dyna -mic x Tracking & compare historical data quality defect rates in the packing station before and after applying the system x Specialist auditor from CS&Q department reviewed system and marked based on FMEA x Specialist auditor from CS&Q department reviewed system and marked based on FMEA x Request specialist auditor from CS&Q department review system and mark based on FMEA % month Method description x Use LDS data to track data follow rate quality for month compared with last month 76 Cycle time x Use stopwatch & the software Equinoxe methodstime measurement (MTM) x Use stopwatch & the software Equinoxe methodstime measurement (MTM) second Preventive maintenance time minute Preventive maintenance step step 1 x Define process flow 4.2 Data collection/Experiment implementation Static test: In SEMV, the RPN score will be reviewed and scored based on the company’s standards by the CS&Q department There are two typical types of testers in SEMV: Manual tester – which required manual action from the operator and Semi-auto which only required operators put the product inside of it The occurrence for manual testers will be cause operators have to press the buttons on the tester In contrast, with a semi-auto tester, the tester will automatically test the product whenever the product is put in which reduces the occurrence to The detection score of this failure mode will be based on the dot-mark function of each tester, meaning that when a product is assumed passed by the tester, it will punch a hole at the base of the product as detection and reduce the detection score to Table 14: RPN Analysis for bypass testing METRICS (S) The severity of the effect of failure (Score) (O) Occurrence of failure mode (Score) (D) Detection of failure mode (Score) Total RPN (Score) BEFORE APPLYING AFTER APPLYING 7 MANUAL 343 SEMI-AUTO MANUAL 196 SEMI-AUTO 49 By using the electronic scale, the system can check the weighing of the products and detect if a box or a product is missing components However, there are some small accessories such as sub-nails packages or instruction papers, the system cannot detect due to the error of the scale and the weight of those accessories smaller than the set tolerance of 5% of the product The detection by weigh scale was applied at the line before the Interlocking, so the score for detecting missing parts remains the same Although it reached the requirement, we already have ideas for improvement and will work on it in the future 77 *Note: The meaning of the color already mentioned in table Table 15: RPN Analysis for the missing package METRICS (S) The severity of the effect of failure (Score) (O) Occurrence of failure mode (Score) (D) Detection of failure mode (Score) Total RPN (Score) BEFORE APPLYING AFTER APPLYING 7 1 49 49 Our system can also auto-print the label right after a product is packaged and not using the pre-printed labels Thus, the label printout by the application will be based on the database setup, so there will be no error about wrong label information Therefore, the occurrence score decreases from to The detection is still visual so there is no change in detection Table 16: RPN Analysis for the wrong label METRICS (S) The severity of the effect of failure (Score) (O) Occurrence of failure mode (Score) (D) Detection of failure mode (Score) Total RPN (Score) BEFORE APPLYING AFTER APPLYING 7 7 343 49 In parallel, the week-code on each label is auto-generated follow real-time, so we successfully in reduce the occurrence to for the failure mode wrong week-code Table 17: RPN Analysis for wrong week-code METRICS (S) The severity of the effect of failure (Score) (O) Occurrence of failure mode (Score) (D) Detection of failure mode (Score) Total RPN (Score) BEFORE APPLYING AFTER APPLYING 7 49 These steps and requirements below are the collected data from the Maintenance team’s reports There is total steps need to for each production line: 78 Maintenance instruction: Figure 105: Maintenance checklist Dynamic Test: Figure 106: KE on 2022 November tracking by LDS system Figure 107: KE on 2022 December tracking by LDS system 79 As shown in figure 106, the KE in November before the applied Interlocking is around 87% and could be seen from the chart that the manufacturing process is not stable A month later in December, the result was after applying the Interlocking system As can be seen from figure 107, the KE day by day is becoming more stable Despite there are still some days we not reaching the required KE due to the incorrect database, tester breakdown, or some other objective reasons, this is still a better improvement The KE in December is around 91%, an increase of 4% compared with before applying the Interlocking system Figure 108: Cycle time analysis after applying the Interlocking system As shown in figure 108, the cycle time of each reference in a particular family “029 AVATARON” is measured by the methods-time measurement (MTM) team and summary The cycle time increased from 2.2 to 2.6 seconds for all of the references in the family In detail, the root cause comes from the scale having some delay time to stable and send the signal to the system, then the system needs some time to process and send the signal to devices The conclusion from KE analysis and cycle time measurement is that applying the Interlocking system is not impact production KE, but also slightly improves it Table 18: Test Criteria Specification name IR Unit Defect Rate time Idea value Marginal value N/A Measure value % Match 100% RPN of bypass testing Score 49 N/A 196 49-196 100% RPN of the missing package RPN of the wrong label RPN of wrong week-code 4 Score Score Score 49 N/A N/A N/A 28 196 28 49 49 0% 100% 100% KE % 90 88 N/A 91 100% Gap cycle time second N/A 2.5 2.4 100% 80 Preventive maintenance time minute 50 N/A 30 45 0% Preventive maintenance step step N/A N/A 100% The average % match without the IR multiplier 77.78% The average % match with the IR multiplier 81.81% 4.3 Summarize + It can be concluded from the above tables that the Interlocking system achieves about 82% the original criteria and is suitable for application in production Although some failure modes have not achieved the desired goal, we are heading toward a new improvement for it + The preventive maintenance time and time to modify/set up with 0% in the percentage of matching but it is not a serious issue The importance rate of this specification is just so this is not affecting the expectation of the system too much + Interlocking system using indoor resources and the investment cost for devices is in an acceptable range SEMV has planned to apply Interlocking for 13 more lines and the process is underway 4.4 Final Specification Table 19: Finalize specification SPECIFICATIONS OF PRODUCT No Specification name Imp Unit Value Group Defect rate time BASIC RPN of bypass testing Score 49-196 BASIC RPN of the missing package Score 49 BASIC RPN of the wrong label Score 49 BASIC RPN of wrong week-code Score BASIC KE % 91 BASIC Gap cycle time second 2.4 BASIC Preventive maintenance time minute 45 BASIC Preventive maintenance step step BASIC 81 Chapter : CONCLUSION, IMPROVEMENT, FUTURE PLAN, AND RECOMMENDATION 5.1 Conclusion Based on the set goals and data reviewed in chapter 4, we can consider that the Interlocking system has reached 80% targets: - Achievements: + Using SQL server to manage product database as global data + Connected with the previous application – Traceability – for printing and creating historical data + Successful in preventing bypass testing station and stored product tested results However, this still required operators to follow operation work standards to fully control the system + Auto-printing kinds of labels based on the database and weighing scale and updating packing history to the SQL database Combined some interlock functions to detect invalid products from the testing station through scanning QR labels + Application built up by indoor human resources + Eliminated the pre-printed labels and reduce change over time + Increase KE > 90% compared to 87% in November 2022 - Limits: + Increase product cycle time due to adding process steps + Slow printing time due to delay in communication between devices and apps + The logic of the testing application still has some block points if the operation is not done correctly + Packing application cannot detect small parts due to the weighing scale error + Required longer time for maintenance devices and cells + Device’s investment cost about 4300 dollars for one production line + Each label has its template leads to difficulty in controlling information alignment 5.2 Improvement - Built up a new function for detecting product labels by scanning content on the label and compare with data on the SQL database - Solutions for the small parts detection: propose to apply a QR label on each part and require scanning to ensure the process → Risks: Increased cycle time, drop KE, and change process or materials design required approval from many levels which take lots of 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