Client Goal

• Integrate system with Pinpoint Data Management system
• Provide information and supervisory control to two production lines with over thirty operator stations
• Integrate conveyors, RFID, and barcode readers
• Provide operator graphical user interface and supervisory control functionality
• Provide critical backup functionality in the PLC for data server failure

Project Overview

Tegron was commissioned to provide the turnkey systems integration of a new assembly process for a major, tier-one automotive supplier. The scope of the project included production line conveyor controls, Pinpoint Data Collection System, and all auxiliary automation equipment.

Our client is one of the world's leading automotive interior systems suppliers. They produce fully assembled, installation-ready seating systems for automobiles and light trucks. The facility in which this project was executed provides seats to a General Motors (GM) assembly plant, and the launch of re-designed products required the complete replacement of two of the facility’s three assembly lines, with minimal interruption to the production schedule. 

The initial Tegron design included network communication requirements, distributed IO, and data collection/presentation to the conveyor controls, a Pinpoint Data Collection system, and auxiliary automation equipment. Each of the new lines included over thirty operator stations. The system was designed to use ContolLogix PLCs and allowed ”Normal” and “Backup” mode tracking of product data to produce proper assembly and quality assurance data, allowing the supplier to meet GM criteria for just in time (JIT) delivery of product critical to the GM assembly plant. Our design guaranteed the continuation of operations in the event of loss of the Pinpoint high-level Data Collection system, via “on-board” tracking of specific build sequence data. Tegron worked closely with all suppliers to assure a common tracking data structure and consistent handshaking for all required production station operations, mechanical as well as data exchange. 

Extensive testing and training were conducted to ensure data reliability prior to product launch. Tegron provided around-the-clock support during the actual launch to ensure timely product delivery. 

Scope of Supply

Turn Key Plant Automation

• Electrical Design
• CAD Documentation
• PLC Software Development
• Control Panel Fabrication
• HMI Development
• Integrated Testing
• System Start-up and Commissioning
• System Training

The Outcome

Close cooperation between Tegron and the conveyor manufacturer allowed a standard PLC processor to handle both conveyor control and data tracking functions at significant cost savings. Critical backup functionality enables the Tegron system to run when the higher-level data management system is offline. Tegron’s project execution team provided a successful product launch, on time and on budget!