Automotive

Traceability Solutions
Automotive Industry - Success story
Automotive Industry Challenges
Automotive parts manufacturers play a vital role in the
supply chain of automobile production, and the reliability
of their products are ultimately responsible for the
safety of human life. In the United States of America, car
company recalls have hit an astounding 53 million vehicles
in 2016 due to faulty parts; the biggest recall cases being
for a major airbag manufacturer.
In discrete manufacturing environments such as the
automotive industry, it is becoming imperative for
companies to shift from error prone manual processes
to traceable automated ones. Recalls can be a car
company’s biggest nightmare since associated costs
adversely affect its bottom line, reputation and brand.
Manufacturers should adopt forward thinking solutions
for their survival.
benefits of the combination of traceability with Big Data
analytics include leaner processes with fewer errors,
faster supply, shorter throughput and greater production
transparency.
How OMRON’s Traceability Solution can help
your business
Aside from witnessing significant growth in profits,
companies adopting traceability can actively participate
in developing a sustainable and safe production process.
However, to meet this goal, precise facts and real
operating data must be readily available for analysis,
strategy formulation and implementation. This is possible
with Omron’s Traceability Solution which has these
characteristics:

Challenges in Imperative
automotive manufacturing actions
Fast
ultra high-speed Reliable
Manufacturing Minimise errors computing with cutting data stored in real time
errors to avoid recalls edge processors without loss of integrity,
for high-speed even during network failure
automation platform

Competitive Improve production

pressure efficiency
Easy
Quality Assured direct access to database
fast identification of faulty using Function Block
Compliance Meeting the parts and tracing of lost instructions, eliminating
items meets quality the need for 3rd party
mandates quality standards assurance targets line side gateway
systems
Table 1 : The challenges of automotive manufacturing Intelligent
data collated helps monitor
patterns more accurately for
The power of traceability solutions combined predictive maintenance
analysis and action
with big data
A Traceability Solution is a process to record, verify and
monitor the source and application of any component
by documented identification. It involves consistent and
reliable checking of the multiple parts and subassembly
processes at every step.

Component data information is read before assembly as

well as at the final assembly inspection, and the complete
production data is collected in real time. This data is then
analyzed for quality improvement and parts tracking. The
We are happy with the professional
delivery, data reliability and results of the
Omron Traceability Solution and we
can see the advantages it brings to our
manufacturing operations. We would like
Omron to extend this solution to automate
the rest of our production lines.
Customer’s quote
The benefits of automation - A Success Story
Customer background
Our key customer is a leading manufacturer of motor
vehicle parts and accessories in Thailand that supplies a
wide range of turbochargers for automobiles. They have
research and development, production facilities and sales
teams in the U.S., Europe, Thailand, China and Korea and,
they are growing competitively worldwide.
Thailand’s automotive sector has developed into the
biggest automotive hub in Southeast Asia and is one of
the largest in the world. Set in this highly competitive
environment; our customer continuously strives to
remain at the leading edge. They also understand
the business risks associated with defective parts
and components leaving the production lines of car
manufacturers every year. The impact of this is not only
the direct costs of recalls but extends to the possibility of
a tarnished brand and reputation over time.
Manufacturing automation solution
To mitigate these risks, our customer made the decision
to invest in our Traceability Solution for operational
excellence. The Omron technology enables them to
collect and utilise real-time traceability data from their
final assembly lines on our reputable Sysmac Machine
Controller to ensure manufactured product quality. This
data is also available for analysis and reporting to achieve
optimum productivity and profitability. The OMRON
Traceability System will continue to help to define and
to develop a sustainable, profitable and safe production
process. Considering this solution, customer can aim for
zero-defect and non-stop production.

The customer had the following objectives when incorporating Omron’s Traceability Solution:

Objectives Omron Solution Customer Benefit

Real-time • Operating status and quality data can be captured, • Customer experienced high data integrity as opposed
big data managed and visualised in real-time to Line PC solution which is exposed to risks of security
management • Direct access to databases without 3rd party line side breach and unexpected network failure
gateway system • Customer can easily capture and share data for
• Seamless database connectivity to Microsoft SQLServer, quality audit
Oracle, IBM DB2, MySQL and Firebird

Precondition Control • NJ is an integrated Automation Control created for • Customer has implemented automated pre-condition
Checking to prevent complete control over the entire automation system. checking instead of manual checking which is prone to
process skipping • Integrates configuration, programming and monitoring human errors
and selection of to protect the process sequence at the assembly line
wrong parts from accepting “No Good Product” or “Wrong Model”

Support Multiple Model
Entries (flexible and
scalable to adapt
to manufacturing
floor requirements)
• NJ is a multi-tasking controller and fully compliant with • Model changes now take less than 30 minutes
IEC 61131-3 programming standard compared to when using Line PC, which was time
• Speedy, reliable and scalable software centric consuming due to complicated programming
architecture enables changes to be made easily and communication

System Architecture Sample

Ethernet
Wide Variety of
Industrial Automation Products
1
Check serial no. (DMC Send DMC Code Machine
Code) from Database. PLC #1
Receive serial no.
* For start process Vision System

Send DMC Code Machine RFID Vision

NJ PLC #2 Laser Bar System
Receive serial no.
Server Controller Code Reader
Traceability 2
Record result to Machine Sensor
Database. Send result PLC #3
* For finish process
Proximity
Sensor
Photo Electric
Available Communication: Sensor
Ethernet

* The above is an illustration of a single NJ station. There are typically multiple NJ stations and PLCs.
What are OMRON’s other Automotive Solutions?

Integrated Process Quality Inspection with Visions Inspection and Traceability

Management System
To improve work processes by preventing
defect outflows due to operational mistakes
using error-proofing (Pokayoke) mechanism.
and Robots
A system that automatically inspects total
engine quality using robots and high
speed visions solution, irrespective of
models and variants produced in the daily
production line.
Incorporating highly accurate inspections
via Omron Vision Solutions into Traceability
will help eliminate bottlenecks in production
lines by identifying defects or errors.

The OMRON Advantage What are the advantages of partnering

with us?
At OMRON, we understand the complexity in the
automotive manufacturing environment from our vast
combined experience of experts and past projects. We
Choose from
also have an extensive collaborative network in the Asia a comprehensive
Pacific Region. Our dedicated specialists will help you product range of over
to select the right solution architecture to meet your 200,000 products like
motion and vision
requirements. You will enjoy our professional service at sensors, safety devices
your door step and we ensure the project delivery and and robots
result complies with your high expectation. Combined
with our world class customer support, we provide the
best possible value while dramatically reducing your cost
of ownership. Stay ahead of the
competition with
cutting-edge
Why choose Omron? solutions

Regional Trusted
World-class Committed network of global
customer to Improve your
automotive automation business operations
support excellence expertise partner with an interactive
combination of
products and
solutions

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