TOYOTA Shop Floor Application Presented by Kevin ONeil

TOYOTA Shop Floor Application Presented by: Kevin O’Neil

Radio Frequency Identification Vehicle Tracking System Mirtec Technologies Presented by Kevin ONeill

AGENDA • Mirtec Technologies - Geographical Coverage - Services - Systems - Industry - Future • Project Details - Toyota SA - Requirements - History - Project Phases

AGENDA • Application - Phase 1 – Description – Criteria – Software and Interface – EMS Products – Duration & Value - Phase 2 – Description – Criteria – Software and Interface – EMS Products – Duration & Value • Costs & Benefits • Competitors • Conclusion • Q&A

Company Details

MIRTEC TECHNOLOGIES System Engineers and Integrators Established - 1988 Services - Design and Engineering Feasibility Studies Systems Integration Installation Commissioning Consulting Distributors Systems - Batching Systems SCADA Field bus Systems Control and Automation Tracking Systems (Since January 2000)

MIRTEC TECHNOLOGIES Industry - Coal Fired Power Generation. - Platinum, Gold and Chrome Mining and Refineries. - Pulp and Paper. - Automotive. - Petro-Chemical. - Food and Beverage. - Material Handling Future - Radio Frequency Identification

MIRTEC TECHNOLOGIES Location Durban South Africa Major Industrial City and Port Situated on the East Coast. Offices Map Relation Employees Total 18 employees consisting of System Analyst's, Engineers and Field Technicians.

MIRTEC TECHNOLOGIES Geographical Coverage

MIRTEC TECHNOLOGIES Geographical Coverage Durban Main Port

MIRTEC TECHNOLOGIES Geographical Coverage Durban Main Port Elizabeth Automotive Industry

MIRTEC TECHNOLOGIES Geographical Coverage Johannesburg Industrial Capital Durban Main Port Elizabeth Automotive Industry

MIRTEC TECHNOLOGIES Geographical Coverage Johannesburg Industrial Capital Durban Main Port Elizabeth Automotive Industry Cape Town Agricultural Sector

MIRTEC TECHNOLOGIES Geographical Coverage Johannesburg Industrial Capital Africa Future Durban Main Port Elizabeth Automotive Industry Cape Town Agricultural Sector

Project Details

THE COMPANY SA Manufacturing • Founded 1961 • Importer, Assembler, Manufacturer and Marketer of Motor Vehicles, and Motor Vehicle Parts and Accessories. • Also has the agency for Hino Trucks • 6700 Employees • 6 Billion Rands ($860 Million) Turnover • Market Leader for the last 21 years – Presently 24% of South Africa Market Share • Future plans to export to Australia – Therefore working towards WCM (World Class Manufacturing) • Plant Production capacity - 500 Vehicles per 8 hr shift. • Current Production – 360 Vehicles per shift (96 400 per Annum). • Manufacture 6 Models – Tazz, Corolla, Camry, Condor, Hi-Lux(Pick Up), Hi-Ace (Mini Bus Transporter)

PLANT LAYOUT & PROCESS FLOW Distribution Yards A Yard Body Shop Paint Shop Assembly Hall TOYOTA SA MANUFACTURING (TSM) Vehicle Final Line Train TOYOTA SA MARKETING (TSB)

PLANT LAYOUT & PROCESS FLOW Distribution Yards A Yard Body Shop Paint Shop Assembly Hall TOYOTA SA MANUFACTURING(TSM) Vehicle Final Line Train TOYOTA SA MARKETING(TSB)

COMPANY REQUIREMENTS • Due to the introduction of SAP into TOYOTA , it was realized that an Automatic Tracking System had to be implemented. The main reason being to ensure Real Time WIP (Work In Progress) information for use on the shop floor, stock control and Financial Management • To achieved this the ultimate objective would be to have the Auto Tracking operational from the start of the production process (Body Shop) through to Vehicle Distribution throughout the country.

HISTORY • Job cards Processed Manually. • Vehicles moved no faster than the paper work flow. • Fitment and distribution planning was done only on what had physically reached a workstation. With a result - no forward planning. • Stock holding in the Distribution Yards was 3 days due to manual paper work processing. • NO REAL TIME DATA!!!!!

PROJECT PHASES Toyota’s decision was to introduce an Auto Radio Frequency ID Tracking System within the plant and implement this in two phases. • Phase 1 – Paint Shop (Dollies and Hangers) – Dual purpose installation - Tracking of Vehicles - Tracking of Vehicle Carriers for maintenance purposes • Phase 2 – Complete Process Fixed RF Tag on the vehicle throughout overall process capable of withstanding harsh paint shop environment.

PHASE 1 • Tag Mounting - HANGERS - DOLLIES

PHASE 1 Hangers – Process Data Method Temp - Pre-degrease - Degrease 2 - Water Rinse 1 - Zinc Phosphate - Demineralized Water Rinse - E-Coated at 300 VDC Electrolytic - Rinse Diptank Spray 30 °C Spray cold water 50°c – 55 °c Cycles : 1. 09 per day – 288 per annum 50°c – 55 °c

PHASE 1 DOLLIES – Process Data Duration Temp Primer ovens 1 -4 - Oven Zones 1 - Oven Zone 2 - Oven Zone 3 - Oven Zone 4 8 mins 195 °c 180 °c 170 °c 165 °c Colour ovens - Oven Zones 1 - Oven Zone 2 15 mins 215 °c 165 °c Cycles : 2. 13 per day – 563 per annum

PHASE 1 13. 5 MHz International standardized frequency Products Used

PHASE 1 13. 5 MHz International standardized frequency Products Used • RF Tags - HMS 150 HT - Quantity 500

PHASE 1 RF Tags - HMS 150 HT - Passive (No Batteries) - Read/Write - 736 bytes memory - Baud Rate 9600 - -40 °C to 240 °C - Reusable - NEMA 6 P/13(IP 68)

PHASE 1 13. 5 MHz International standardized frequency Products Used • RF Tags - HMS 150 HT - Quantity 500 • RF Readers– HMS 820 - Quantity 14

PHASE 1 RF Readers– HMS 820 - Integrated Antenna - 4 Input/Output points - Host Interface (Com 1) -RS 232/RS 422/MUX 32 - Auxiliary RS 232 serial port. - 1000 bytes/sec transfer speed. - NEMA 4 (IP 66)

PHASE 1 13. 5 MHz International standardized frequency Products Used • RF Tags - HMS 150 HT - Quantity 500 • RF Readers– HMS 820 - Quantity 14 • Interface module – MM 80 - Quantity 1

PHASE 1 MM 80 Micro. Mux – Bus module - RS 232/RS 485 converter - Mux 32 protocol - C programmable - 9600 & 346 K baud communication - Network up to 32 devices

PHASE 1 Software and Interface • In-house Custom Written Software • Visual C++

PHASE 1 Software and Interface - 2 Alternate interfaces - RS 232 to Token Ring Thin Client (VTS) - RS 485 (Mux 32) to EMS Data base (Maintance)

PHASE 1 Duration & Value - Total Project 12 weeks - Cost R 600 000($85 000)

PHASE 2 • Description Tracking of Vehicles. 96 400 Units per annum.

PHASE 2 • Criteria - 6 different models. - No common mounting position. - Withstand Harsh conditions (200°c). - Cost < R 35 ($5) per Tag.

PHASE 2 13. 5 MHz International standardized frequency Products Used

PHASE 2 13. 5 MHz International standardized frequency Products Used • RF Tags – LRP 250 HT-FLX - Quantity 96 400 per annum

PHASE 2 RF Tags - LRP 250 HT-FLX - Passive (No Batteries) - Read/Write - 48 bytes memory - Reusable or Disposable - Adhesive backing - -40 °c to 240 °c - NEMA 6 P/13(IP 68)

PHASE 2 13. 5 MHz International standardized frequency Products Used • RF Tags – LRP 250 HT-FLX - Quantity 96 400 per annum • RF Readers– LRP 820 -08 - Quantity 71

PHASE 2 RF Readers– LRP 820 -08 - Read/Write multiple tags simultaneously - 4 Input/Output points - Host Interface (Com 1) -RS 232/RS 422/MUX 32 - Auxiliary RS 232 serial port. - NEMA 4 (IP 66)

PHASE 2 13. 5 MHz International standardized frequency Products Used • RF Tags – LRP 250 HT-FLX - Quantity 96 400 per annum • RF Readers– LRP 820 -08 - Quantity 71 • Portable reader – Formula 7400 - Quantity 5

PHASE 2 Portable reader – Formula 7400 - I. Code Identification - Read RFID and Barcodes. - Based on a 486 processor. - Integrated full RS 232 and Ir. DA Ports

PHASE 2 13. 5 MHz International standardized frequency Products Used • RF Tags – LRP 250 HT-FLX - Quantity 96 400 per annum • RF Readers– LRP 820 -08 - Quantity 71 • Portable reader – Formula 7400 - Quantity 5 • Pass through Gate Antenna - Quantity 1 • Interface module – MM 80 - Quantity 9

PHASE 2 Software and Interface • RS 232 interface with Token Ring Thin Client within TSM Production Plant. • RS 485 Multi drop Network throughout TSB Distribution Yards. Interfaced to TSM via Token Ring Gateway. • Wonderware IN-TRACK software. • SAP Management System

PHASE 2 Duration & Value (Excluding Software and Token Ring Network) - Total Project 6 months - Cost R 1. 6 million ($230 000) - Tags monthly consumable.

COSTS & BENEFITS • Phase 2 Overall Vehicle Tracking Project - R 9 500 000 ($1. 357 000) - Manual data capture – redundant - Real Time/Work In Progress information available. - Reduction of Stockholding. “ONE DAY STOCK REDUCTION EQUATES TO R 35 ($7) SAVING PER UNIT IN FINANCING COSTS” 96 400 Units per annum @ R 35 = R 3 374 000 ($482 000)

COMPETITORS • Siemens • Baumer Ident • Impro (SA) – First two competitors products very expensive – Third competitor products failed during trials

CONCLUSION • It is believed that this VTS project will move TOYOTA towards World Class Manufacturing.

Q&A ?