Turnkey Automation and Controls Solutions

When it comes to the automotive industry, improvements are happening every day. For over 20 years, our team has been integral in the processes and progress needed to keep our Tier 1 Automotive Parts Manufacturer customer at the top of their game.  

We started by providing the automation and controls for their automotive part systems. This included creating the machine’s program and algorithms to test physical, electrical, and electronic functionality – all while running within a demanding production floor environment. The program tests parts against their required specifications all while collecting data that can be used in statistics, quality control, and production considerations.  

Our customer has recognized the value of our part testing system to the degree that we’ve become their complete solution provider and integrator across five of their facilities. Throughout these facilities, we’ve designed and implemented all of their data collection, methodologies, and interfaces from the ground up with tailored designs and dashboards.  

Using SE Data Pro and custom software solutions we provided the following services:  

• Asset management
• Part information management
• User management
• Part production scheduling
• Dashboard visualization of production metrics on the shop floor
• ERP system integration
• OEE reporting
• Machine/station state reporting  

Here is a more in-depth look at the work we’ve completed: 

Voice Annunciation Alert System  

Our team developed and integrated a voice annunciation alert system into the plant that uses speech and text to dial into the existing PA system. When a machine requires maintenance or immediate service, the system uses a voice modem to alert what machine is faulting and what specific action needs to take place. Service is able to be rendered quickly and efficiently.  

Data Collection 

Using our in-house, ground-up data collection software, our customer can collect and store part recipe metrics to allow for increased quality control. This information also allows our customer to monitor equipment efficiency, machine status, and assistance calls. Data collection also provides part traceability for production processes and connects the shop floor authentication needs to the authentication service.  

Our software is integrated across all stations and is equipped to monitor and archive all types of testing. Across all of the facilities we serve, we are currently collecting data on over 38,000 tags, 400 controllers, and 586 stations.  

Production Scheduling and Monitoring 

Schedules are easily created and integrated onto the plant floor. This helps achieve a paperless system while also allowing customer requests to be integrated into plant floor activities. 

Automotive Electronic Testing  

We provided a variety of specialty testing systems that enable long term part traceability. These systems trace everything from backup cameras and electronic handle serial number information, to the finished good's part serial number. This testing not only improves quality control but also provides traceability production data in the case of a part recall. 

Machine Status Dashboards and Reporting 

In order to increase production and equipment visibility, our team installed and designed dashboards at each production line. These dashboards display periodically refreshed production data as well as equipment faults and top part faults. This allows designated personnel to focus on the highest occurring faults in both count and duration leading to more informed and targeted maintenance. With the increased awareness and realization of loss and issues, overall downtime is decreased. Our team also created interactive dashboards that allow individuals to browse and filter past data.  

Upgrading Hardware  

Over 25 years ago, our team installed the initial HMI and PLC systems in the plant. Recently, our team had the unique ability to upgrade those same systems and retrofit them into our data collection software. We are also continuously helping our customer develop and improve their data collection standards so that their OEM integrates with the customer’s current data collection process.  

User Authentication Service  

Our team designed and built a custom authentication service that provides traceability, access control, and security on their plant floor. The user authentication service uses required inputs to track, store, and monitor equipment users.