YANMAR CONSTRUCTION: production monitoring, traceability and performance


"Many features are delivered! Display of work instructions on each workstation according to the current operation, traceability of all quality controls, traceability of major components (serial numbers) of the machine produced, control of production indicators, management and traceability of different alerts, display of work in progress..."

With three production sites based in Saint Dizier(Yanmar Construction Equipment Europe), in Crailsheim (Yanmar Construction Germany) and in Fukuoka (Yanmar Construction Equipment), the unit Yanmar Construction produces and distributes compact construction equipment designed for public works, construction, landscaping, pipe laying, demolition and civil engineering.

A specialist in compact equipment, Yanmar offers a full range of machines including conventional track excavators and Zero Tail Swing, carriers, compact wheel loaders and accessories. ORDINAL Software's COOX solution was chosen to monitor the production, performance analysis and traceability of the Saint-Dizier site. Through the three PMT (process traceability), MTG (Material Traceability) and QPI (Quality, Performance and Indicators) modules, the COOX platform will first be integrated into the workshop "assembly of construction machines", then into a second time, the application will be deployed in the rest of the factory.

1st slide :

View for the production manager which allows him to have a global vision of performance and defaults for each position.

2nd slide :

COOX standard view which allows to display the Production Orders planning for the day or for the current week.

3rd slide :

Production Orders import from the ERP via a CSV file => display of the CSV file which includes all of the Production Orders, with the following parameters : execution date, priority, range, options, quantity, etc.
For example, the 1rst Production Order includes 3 mini-excavator, a cabin, tracks and a balance wheel.
The second Production Order of the mini-excavator includes 5 options: the cabin, the tracks, the radio, the air conditioning and the balance wheel.

4th slide :

CSV file submission.

Production Orders CSV file is deposited in a dedicated directory. It is then automatically imported every day at midnight and then moved to be stored in the Archives directory.

5th slide :

The two Production Orders are then created. Each of them is divised into two work orders. A Production work order which resumes the range of the mini-excavator with its different options (cabin, track…) and a Control Work Order attached to an inspection range, dedicated to quality.
The Work Orders are then automatically executed according to the estimated date of execution even if COOX also allows to launch individually in manual

6th slide :

Visualization of the Production Work Order on the CIN20 station.
This view is intended for operators of the CIN20 station. It indicates to the operator the Production Order to perform, the reference of the machine, the type of operation to perform, the necessary tools : a diagram or an image is displayed.

The operator is also shown at the bottom of the screen the estimated time for this task :here, 1 minute. Other indicators are also available, such as daily production, i.e. the quantity of mini-excavators to be produced for the operator, here he has 9 left.

With the configuration button, the operator accesses the various options of this machine (cabin, track, balance wheel…).
After 1 minute, the next task will be automatically displayed even if the operator can, if he has already finalized his task, activate the next one.
Here, the next task is the verification of the tightening torque, with a video illustrating the task, then, move on to the next task : installation of the hydraulic component with display of an assembly plan, then assembly of a flywheel…
A button is also available which allows the operator to view the previous task (here, installation of the hydraulic component).
If a problem appears on the workstation, the operator must click on « call » in order to alert production, logistics or quality and declare a production, logistics or quality stop.

When declaring a stop, the station turns red to indicate that it is stopped.
Then, the operator can trigger the restart of the station. The validation key allows him to increment the number of machines he has produced, here, in our case, 10.
So, the different steps are repeated to produce the 11th machine, and so on…

7th slide :

Control Work Order execution.
The quality selects the Control Work of Order which it will carry out.

8th slide :

Visualization of the Control Work Order on the CTR10 station.
On the CTR10 HMI, we can see the Work Order to control, the type of machine and the types of control.
For example, here : does the pressure self-regulated pump correspond to the visual support image ?
=> OK / NOK.
If this is NOK, the controller must inform the concerned module (electrical module, hydraulics, documentation…), the type of default (jammed, loose, etc.) using the drop-down list.
In comments, he can indicate that there is a light on.

Another type of control can also be carried out with photos. COOX software offers the operator 4 photos of their choice, to the controller and the controller must select the photo corresponding to the model of the manufactured excavator.
Then, he informs the concerned module, the type of default and adds in comments « non-compliant ».

You can also perform an aspect check. A grid with a mini-escavator is displayed, then the controller can select a box in the grid (ex : D2) and indicate the type of default (chip, …), and select another zone (A3) and indicate a flowing default. 
He can also move around the escavator by selecting for example the back of the machine and declaring another defaut (C2 : missing).
At the end of the aspect checks, a summary is offered to the controller.
Then, he enters the machine serial number and attaches all of the controls to it.

9th slide :

Repair visualization

Following the various checks, a repair Work of Order will be created, based on the details given by the operator.

An HMI station dedicated to repairs indicates the various data from the checks and offers in a drop-down list the various data to be entered in order to repair (causes, sector manager…).
Then, the state goes to repair « OK ».
The second Work of Order goes through the same steps.

10th slide :

Data visualization.
We can see the initial table which indicates the list of aspects defaults, recording defaults and work in progress updating (done repairs).

For confidentiality reasons, some pictures, illustrations or names have been deleted or replaced.