Steeplechase Used by Automotive Tier 1 Supplier for ILVS Manufacturing
25 February 2000
Steeplechase Used by Automotive Tier 1 Supplier for First-Ever 'Batch of One' In-Line Vehicle Sequencing (ILVS) Manufacturing
Donnelly Achieves Record Startup Time and Significantly Improves
Output with Steeplechase PC-Based Control
ANN ARBOR, Mich., Feb. 24 -- Steeplechase Software, Inc., the
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. Steeplechase's award-winning software was
selected based upon its power and high performance, and ability to meet
Donnelly's automation goals. Donnelly Corporation's customer list includes
every major automobile manufacturer in the world.
Because of the ability of PC-based control to closely integrate with
manufacturing Information Systems, Donnelly 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 colors 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 colors 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-molded housing in a specified color, 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 colors 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.
About Steeplechase
Steeplechase Software, Inc., is the undisputed leader in PC-based logic
control according to ARC Advisory Group, and is recipient of the 1999 Frost
and Sullivan Market Leadership Award for PC-based Controls. Founded in 1993
by veterans of the PLC industry, Steeplechase provides productivity-based
automation tools to Fortune 500 manufacturers and OEMs that cut control system
design, installation and launch times, and lower machine downtime. For
additional information, call 734-975-8100 or visit http://www.steeplechase.com .
About Donnelly Corporation
Donnelly Corporation is an international automotive supplier dedicated to
serving customers around the globe with industry-leading components and
systems in automotive mirrors, windows and door handles. The company, in
business since 1905, has 5,500 employees and operates in 12 countries
worldwide. For additional information call 616-786-7000 or visit
http://www.donnelly.com .
About DVT Corporation
DVT is a proven leader in vision systems and automated on-line inspection.
Over 5,000 SmartImage Sensor Systems are currently in use, including many at
Fortune 500 companies. For more information call 770-449-4960 or visit
http://www.dvtsensors.com .