Sistema pick-to-light per stazioni di assemblaggio di paraurti
Presso lo stabilimento di Zwickau, il fornitore del settore automobilistico SAS Automotive Systems ottimizza la produzione di moduli cabina con un sistema pick-to-light
SAS Automotive Systems produce cabine per l'industria automobilistica, montate singolarmente secondo la formula just-in-time. Per l'addetto all'assemblaggio presso lo stabilimento SAS di Zwickau, in Germania, ciò significa finalizzare un modulo al minuto. Per migliorare questa attività, un sistema pick-to-light indica ora esattamente quale componente deve essere installato e in quale ordine. La soluzione pick-to-light di Turck ha convinto l'azienda SAS grazie all'approccio completo comprendente sensori, sistema I/O e gateway fieldbus, nonché alla sua facile integrazione nella linea di produzione.
Lo stabilimento SAS di Zwickau era alla ricerca di nuovi modi per ridurre gli errori durante il processo di produzione e assemblaggio delle cabine. SAS Zwickau produce cabine di guida per lo stabilimento Volkswagen ubicato proprio accanto. Oliver Graf, uno dei responsabili della progettazione dell'impianto, spiega: "Riceviamo le specifiche circa 2,5 ore prima della consegna e dobbiamo produrre e consegnare le cabine nei tempi previsti". Per essere in grado di produrre un numero massimo di 1.300 cabine al giorno, è necessario completare una cabina di guida al minuto.
Se il controllo qualità rileva un errore al termine della linea di produzione, deve essere corretto manualmente. Il modo più semplice per garantire una produzione impeccabile è integrare il controllo di qualità durante il processo di installazione. Prima del sistema pick-to-light, gli addetti all'assemblaggio leggevano la configurazione della cabina dal foglio di commessa e dotavano la cabina di conseguenza. Non era possibile evitare completamente gli errori.
Meno errori con il sistema pick-to-light
Con il sistema pick-to-light di Turck e Banner, SAS ha potuto ridurre notevolmente gli errori durante l'assemblaggio della cabina. Il sistema traduce la configurazione di una cabina in segnali luminosi, che mostrano all'addetto i componenti richiesti, nell'ordine corretto. Tutti i contenitori di uscita sono stati dotati di un indicatore luminoso e l'addetto deve semplicemente prelevare il componente dal contenitore che si accende e montarlo nella cabina. L'indicatore dispone di un sensore ottico integrato che conferma automaticamente il prelievo del componente. Il sistema verifica i progressi e invia i dati al sistema di controllo della linea di produzione; il sistema rileva il completamento di un ordine e attiva il segnale luminoso per l'ordine successivo.
È impossibile che il sensore ottico si attivi per errore grazie alla funzione di soppressione dello sfondo configurata a 100 mm. Inoltre, il sistema offre un alto livello di protezione, quindi se l'addetto preleva un componente dal contenitore sbagliato, si accende immediatamente un indicatore rosso a segnalare l'errore.
Vantaggio competitivo: approccio sistemico
SAS ha optato per la soluzione di Turck per diversi motivi. Tra questi vi è la conferma automatica del prelievo, ottenuta grazie a una barriera ottica o a sensori alternativi. Turck non era l'unico fornitore a offrire questa soluzione, a convincere definitivamente il cliente è stata l'offerta completa di hardware per la connessione alla linea di produzione, presentata dallo specialista dell'automazione di Mülheim.
Durante il normale funzionamento, 20 stazioni di assemblaggio sono state equipaggiate con il sistema pick-to-light e un indicatore di segnalazione K50 è stato installato in tutti i contenitori presenti presso le stazioni. Un sistema I/O BL20, collegato tramite gateway fieldbus al sistema di controllo della linea, provvede alla trasmissione dei segnali tra l'indicatore e il livello di controllo. Per quanto riguarda il software, sono stati necessari solo piccole modifiche.
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