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CHAPTER 1
INTRODUCTION
The current automotive industry has been enjoying a period of strong growth
and profitability, and annual sales reached prerecession levels in some regions.
Entirely, the automotive industry rapidly continues to increase their profitability
and streamline the operation by continuously improve the production system.
Lean has been successfully implemented in many companies of manufacturing
and services. It has been accepted as a set of multi-dimensional approach with
a set of various principles, techniques and tools. The mixed-model assembly line
(MMAL) is a type of assembly line in which a variety of product models are
assembled on the same line. The use of highly variant parts on the assembly
line need to be considered carefully to enable satisfactory material flow control
and allow for smooth production.
2
The study is concentrated on a new system in lean called Set Parts Supply
(SPS). SPS first introduced by Toyota as a system to overcome the huge parts
variants. It also made to increase the quality of parts supply and parts assembly
in MMAL. SPS contribute to the reduction of wastes.
The supply system of parts from the warehouse to the assembly line is in lot
supply. This kind of system often took a lot of space for racking nearby the line.
Inside the warehouse will be miserable with unorganized parts. Transferring
parts by lot also would cost you undetected defective parts. As it not build in
quality ever since from the warehouse. Using lot supply makes it harder to
integrate with schedule and demands. Cascading down from the planner until
operator, its hard to predict how much does it available in a lot of parts. At the
end of the day, it will harden the material handler.
4
1.3 Research Objectives
1. Study the existing material handling system and analyse Set Parts Supply.
2. Design and create a new prototype of line follower robot with obstacle
avoidance to transport bento box.
3. Fabricate the small model of production line for better understanding of SPS
flow.
This study will be develop and analyse at one of the well-known automotive
manufacturers
and
International
College
of
Automotive
(ICAM)
about
Change the part transfer system from lot supply to Set Parts Supply System
CHAPTER 2
LITERATURE REVIEW
The scope was specified in order to smaller the review of the study as viewed in
Figure 2.1:
Lean Manufaturing
Material Feeding System
Set Part Supply
(SPS)
Autonomous
Robot
Figure 2.1: Pyramid of Study Scope
6
2.2 Lean Manufacturing
After World War II, Engineer, Taiichi Ohno was first developed the principles
of lean production. He was focused on how to eliminate waste and empowering
workers, reduced inventory and improved productivity.
Figure 2.2 shown about House of Lean consisted of several aspects from the
fundamental until the top of the house:
The ultimate goal is placed at the roof and it is customer focus. Customer
focus implies the highest quality, at the lowest cost with the shortest lead time by
continually eliminating waste. However, today customers have broader
expectations than before. Thus, lean companies have added safety,
environment and morale to their core goals. (Dennis, 2002)
Elimination of waste is the core of lean philosophy. In the model, the way to
achieve the ultimate goal is by continually eliminating muda. From a lean point
of view, muda means any activity which the customer is not willing to pay for.
Its not the end of everything as removing muda would be the most ideal
condition of lean. (Bicheno, 2004)
Workers in a lean system should always be ready to see waste and discover
its sources. Therefore, efforts to eliminate waste are never-ending. (Nicholas,
2006) All organizations need to continually improve the ratio of value adding to
non-value adding activities.
2. Waste of Waiting: It takes time when time is not used efficiently. Waiting time
can be by workers, parts or customer and it is not value adding to the
product.
3. Waste of Unnecessary Movement: Employees performing unnecessary
motions such as bending, stretching, looking for parts or walking between
processes create non value adding waste.
9
7. Waste of Defects: Producing defective parts or correction cost time and
money. The more time a defect remains undetected the more cost is added.
For that reason, defects should be determined by prevention methods
instead of inspection.
2.2.1
i.
Man / Woman
ii.
Machine
iii.
Material
iv.
Method
Stability starts with visual management and 5S system. 5S are the keys to
achieve production stability which support standardize work and TPM.
10
5S system is designed to create a visual workplace, which is self-explaining,
self-ordering, and self-improving. 5S also supports JIT production by providing
point-of-use information that eases decision making.
5S leads the organization to TPM, which is the key to machine stability and
effectiveness. TPM is revolutionary in the sense that it changes the mindset of I
operate, you fix into We are all responsible for our equipment, our plant and
our future. (Dennis, 2002)
i.
ii.
iii.
11
Bicheno (2004) explains three key aspects of standard work which need to be
understood:
i.
ii.
iii.
i.
Process stability
ii.
iii.
Organizational learning
iv.
v.
vi.
Kaizen
vii.
Training
The most important elements of standardized work are: Takt time, Cycle
time, Work sequence and In-process stock. Takt time shows the frequent of a
product should be produced. Cycle time is the actual time it takes to do the
process. The goal is to synchronize the takt time with cycle time. Work
sequence defines the order in which the work is done, and should be clearly
defined. In-process stock is the minimum number of unfinished work pieces
required for the operator to complete the process without standing in front of a
machine. Defining in-process stock clearly esteablishes WIP (work-in-process)
standards per process, and again makes abnormalities obvious. (Dennis, 2002)
12
2.2.1.1 Total Productive Maintenance
i.
No Breakdowns
ii.
iii.
No Defects
The traditional approach to TPM was developed in the 1960s and consists
of 5S as a foundation and eight supporting activities (sometimes referred to
as pillars) as shown in Figure 2.3:
13
2.2.1.2 Kaizen
ii.
iii.
iv.
v.
Work as a team
vi.
One of the most notable features of kaizen is that big results come from
many small changes accumulated over time. However this has been
misunderstood to mean that kaizen equals small changes. In fact, kaizen
14
means everyone involved in making improvements. While the majority of
changes may be small, the greatest impact may be kaizens that are led by
senior management as transformational projects, or by cross-functional
teams as kaizen events.
2.2.2
Just In Time
Just-In-Time Just in Time production is one of the walls that built House of
Lean and is based on a pull system. Pull means to produce only when there is a
customer order. The opposite is push, and means producing even if there is no
demand for it. (Dennis, 2002)
Dennis (2002) states that JIT production follows four simple rules:
i.
ii.
15
2.2.2.1 Pull System
The pull inventory control system begins with a customer's order. With
this strategy, companies only make enough product to fulfil customer's
orders. One advantage to the system is that there will be no excess of
inventory that needs to be stored, thus reducing inventory levels and the cost
of carrying and storing goods. However, one major disadvantage to the pull
system is that it is highly possible to run into ordering dilemmas, such as a
supplier not being able to get a shipment out on time. This leaves the
company
unable
to fulfil
the
order
and
contributes
to
customer
dissatisfaction.
Takt is the German word for the baton that an orchestra conductor uses
to regulate the tempo of the music. Takt time may be thought of as a
measurable beat time, rate time or heartbeat. In Lean, takt time is the
rate at which a finished product needs to be completed in order to meet
customer demand. If a company has a takt time of five minutes, which
means every five minutes a complete product, assembly or machine is
produced off the line because on average a customer is buying a finished
product every five minutes. The sell rate are every two hours, two days or
two weeks is the takt time. Described mathematically, takt time is:
Available time for production / required units of production
16
It is important to note that the time available for production should reflect
the total number of hours (or whatever units of time is used) employees work
minus time spent on any breaks or meetings. Required units of production is
a measure of customer demand on how many products a company expects
its customer to buy in a given period of time. That period of time should be
consistent between the two variables in the takt time equation (e.g., per day).
2.2.2.3 Heijunka
17
Furthermore, the disruption of production flow is minimised by making
sure that components are sequenced to be available in the right quantity and
at the right time, while changeover periods for vital processes such as die
changes within the steel presses are as short as possible; often in as little as
three minutes.
18
their changeover times. His pioneering work led to documented reductions in
changeover times averaging 94% (e.g. from 90 minutes to less than 5
minutes) across a wide range of companies. Changeover times that improve
by a factor of 20 may be hard to imagine, but consider the simple example of
changing a tire:
i.
ii.
For a NASCAR pit crew, changing four tires takes less than 15
seconds.
ii.
2.2.3
Jidoka
The other wall which builds House of Lean is Jidoka. This term has been
defined by Toyota as automation with a human mind and implies intelligent
workers and machines identifying errors and taking quick counter measures.
(Dennis, 2002)
19
2.2.3.1 Error-Proofing or Poka Yoke
Error proofing Dennis (2002) states that high defect rates caused by the
errors in production lead to frequent line stoppages, which make flow and
pull, and therefore lean production impossible.
i.
Forgetfulness
ii.
iii.
Errors in identification
iv.
v.
Wilful errors
vi.
Inadvertent errors
vii.
viii.
ix.
Surprise errors
x.
Intentional errors
Hirano (1988) also states that almost all errors can be prevented if the
sufficient effort is put on identifying them and taking steps to prevent them by
using poka-yoke methods. Poka-yoke 12 means implementing simple low
cost devices that either detects abnormal situations before they occur, or
once they occur, stop the line to prevent defects. (Dennis, 2002)
20
i.
ii.
High reliability.
iii.
Low cost.
iv.
v.
2.2.3.2 Andon
Andon is
to
system
to
notify
The system typically indicates where the alert was generated, and may
also provide a description of the trouble. Modern Andon systems can include
text, graphics, or audio elements. Audio alerts may be done with coded
tones, music with different tunes corresponding to the various alerts, or prerecorded verbal messages.
21
2.2.3.3 Autonomation
Autonomation is the strategy that Toyota uses for its machines, rather
than investing in huge monolith machines that can do everything but take
forever to set up and require to run huge batches they invest in small
machines that do specific tasks that humans would find difficult or repetitive
and use autonomation principles to ensure that the operator only has to
interrupt the cycle if something goes wrong. This increase productivity and
reduces costs considerably as now an operator can monitor several
machines on an exception basis and only has to take action if something
goes wrong. (Matt & Rauch,2012).
22
In addition to autonomation they also developed the idea of mistake
proofing known as PokaYoke which seeks to either prevent the possibility of
creating a defect or in highlighting if one has been created. Autonomation is
part of Jidoka, jidoka being a simple set of rules that were inspired by
Toyodas first loom;
i.
Discover an abnormality
ii.
STOP
iii.
iv.
Jidoka covers both the whole process as well as individual machines and
requires that operators who spot an abnormality stop the process in just the
same way that autonomation has the machine stop when something is
incorrect. The important thing however is not to just stop, autonomation
without the follow through of the remaining Jidoka principles just results in
machines that keep stopping.
2.2.4
Involvement
Involvement is at the heart of the House of Lean. The explicit goal of all
involvement activities is to improve productivity, cost, delivery time, safety,
environment and morale by:
i.
ii.
iii.
23
According to Dennis (2002), the deeper goal is to improve team member
capability. By strengthening the employee a company can face the future
confidently.
Kaizen Circle Activity (KCA) is the best known involvement activity. It helps
to strengthen team members their ability to work as a part of a team, as a
leader as well as it improves their ability to thinking clearly and logically to solve
problems. It also supports the team members build confidence. (Dennis, 2002)
Specifying value from the point of view of the customer: The critical
starting point for lean thinking is value. Value can only be defined by the
ultimate customer and it is only meaningful when expressed in terms of a
specific product (a good or a service, and often both at once), which meets
the customer's needs at a specific price at a specific time. (Womack &
Jones, 1996)
Identifying the value stream: Value Stream is all the specific actions
required to bring a specific product (whether a good, a service or a
combination of two) through three critical management tasks of any
business. These three tasks are problem solving or product definition task,
information management task and physical transformation. (Bicheno, 2004)
The value stream map is a tool that: allow you to diagram your current value
stream, identifies the bottleneck that causes the delays and develops a
vision of what your future lean system should look like. Furthermore, it is also
important to look at the whole supply chain, or more accurately the demand
network. Concentration should be on the viewpoint of the object (product or
customer), not on the viewpoint of the department or process step. (Bicheno,
2004)
24
Make the value flow: Making the value flow means working on each
design, order, and product continuously from beginning to end so that there
is no waiting, downtime, or waste, within or between the steps. The ideal
state is a one piece flow at and between processes. This usually requires
introducing new types of organizations or technologies and getting rid of the
obstacles. It is useful to work according to Stalk and Houts Golden Rule and
never delay a value adding activity because of a non-value adding activity.
Instead, such activities should be done in parallel. (Bicheno, 2004)
One of the key decisions for every assembly line is the decision about the
materials feeding system which means the method of supplying materials to
25
the operators. This decision affects all of the other activities performed as well
as the performance of the assembly line.
i.
ii.
2.4.1
Continuous Supply
26
another one from the container. However, there are some disadvantages
too. If there are an excess number of parts to be assembled it means a lot of
capital is tied up in stock, shop floor is becoming overcrowded by the parts,
and the assembly operator has to move a lot to get the parts and loses time
looking for the correct part numbers.
2.4.2
Batch Supply
2.4.3
Sequential Supply
27
2.4.4
Kitting Supply
28
In the studied literature a large variety of different solutions
considering kitting was examined making it very difficult to describe one pure
kitting system. Bozer and McGinnis (1992) observed two types of kits:
stationary kits and travelling kits. The stationary kit is delivered to one
assembly station where it remains until it is fully consumed. The travelling kit
on the other hand travels alongside the assembly object and can support
several assembly stations before it is consumed. Brynzr and Johansson
(1995) further examine the different design options of kitting systems in their
report. The kitting can either be performed by an assembler or by a picker
(i.e. special category of operators) and the kitting activity can be performed
in a central picking store or in decentralized areas close to the assembly
stations. Several articles discusses higher picking accuracy when the
assembler himself is responsible for the whole job since he has a better
understanding for the part numbers included in the assembly operations
(Brynzr and Johansson, 1995; Johansson, 1991). The articles also
recognize reduced administrative work when the picker and the assembler
was the same person.
1. Batching policy instead of picking each kit separately, several kits are
picked together in order to reduce walking distance and picking times
2. Zone picking - a picking order is divided into picking zones and hence can
be picked simultaneously in different zones
3. Picking information picking list is the most common picking information
for the picker but this system has a high risk for inaccuracy through the
picker picking the wrong parts. A display at the storage locations
indicating what should be picked is another alternative, which reduces the
risk for inaccuracies. Another is to assign each finished product a number,
letter or color and displaying this symbol at each storage location.
29
4. Design of picking package the design of the picking package has to
both be functional in the picking process as well as in the assembly
process. The parts can either be displayed lying 6 freely in the package or
fixed with a dedicated placing. A dedicated place for each part reduced
the flexibility of the package but increases at the same time the safety of
the part and the control/speed of the assembly.
2.4.5
Another critical decision about the assembly line is the decision about
order picking activities. Order Picking is the process of removing items from
storage to meet a specific demand. It can be performed manually or partly
automated. It represents the basic service that the warehouse provides for
the customer. In a manufacturing area, assembly line is accepted as an
internal customer for the warehouse. (Tompkins, 1996)
30
Packing items
(2001) recommends
some
methods
reduce
(or eliminate)
Figure Frazelle
2.6: Distribution
of working time
for a
materialtopicker
(Plasecki,
2003)
31
pick locations to reduce searching time and automated dispensing to reduce
extracting time.
i.
ii.
iii.
iv.
v.
vi.
Assign the most popular items to the most easily accessed locations
in the warehouse
vii.
viii.
ix.
x.
xi.
xii.
32
2. Touch items once: Order pick process should allow enough verified
accuracy that further repacking, quality checking, or shipping checking, is
not required. A pick unit should go to the customer (assembly line)
touched only by the original pickers hands.
5. Use ABC item analysis: Prioritization should be done between items. For
example, if 10% of the items can completely satisfy 50% of the orders
(typically true), then these items can be called "A" items. A short pick line
comprised of only these "A" items can be set up, and immediately half of
the orders require walking through only 10% of the pick area.
6. Stop pick and pass line picking: Pass-along picking slows all orders to the
speed of the slowest picker, or, to the capacity of the busiest pick station.
Pick rates of the better pickers can often be increased by 30% to 200%,
just by switching from conveyor picking to individual cart picks.
7. Invest in training and quality circles: Even the best designed order picking
systems undermine its original excellence by changing customer
requirements. An investment in productivity and accuracy improvement
(Total Quality), and management supported quality circles that meet
regularly to identify problems and propose solutions, will pay big dividends
in continuous improvement of even an already excellent system.
33
8. Walk your talk: The least costly and most effective way to improve the
order picking is through direct, continuous and enthusiastic top and
middle management support, of the workers striving for the highest level
of picking accuracy and efficiency. Workers sense immediately, if
management is only giving "lip service" to their commitment to excellence.
Decisions about order picking systems are very important for kitting
because as stated by Bozer & McGinnis (1992) and also supported by other
researches like Brynzer (1995) and Medbo (2008) conceptually kit assembly
is an order picking operation itself.
There are two main jobs in SPS which Erabitori and Kumitsuke. Erabitori or
selection is a process of selected the each part of the different models.
Kumitsuke or assembly is a process in which the parts are assembled on the
car body. The selection process is done by an operator in an area called the
supermarket which is called picking process. The scoped of job focuses on the
selection of the needed parts, removing the unnecessary materials and placing
the selected part on the box. Then, the box is placed on the cart and supplied
to the assembly line. The second job is done by an assembly operator at each
workstation on the assembly line. The assembly operator will pick up the parts
one after another from the box for the related assembly process and
assembled them on the car body.
34
In SPS implementation, for the starting, the point of Kanban is moved from
the assembly line to the supermarket area. There is no Kanban between the
assembly line and the supermarket. The job in the supermarket is synchronized
with the assembly line which is planned by the production planning department.
This means that there is no order for supplying parts from the assembly line to
the supermarket. The instruction to supply parts for the selection process also
comes from the management (production planning control). Therefore the
shopping operator will concentrate on the selection process and the assembly
operator will focus on assembling the parts. This make it easy for the unskilled
worker to understand and the time to train a new assembly operator can also
be reduced. It seems that implementing SPS requires more jobs to be done
albeit with some additional labour cost.
SPS is also known as the kitting supply, however there are certain
elements that make SPS different from kitting. SPS and kitting seem to be
beneficial to solve space utilization and material handling problems but the
kitting process is less understood in terms of flexibility, quality and cognitive.
Kitting requires all the components or subassembly collections to be completed
before being delivered to the assembly line. Otherwise, kitting will lead to poor
quality and increase the lead times due to the rework process. SPS is better
than the traditional method because it can reduce the distance of the parts
supplied by 3% and the total time for part arrangement 4%. SPS also can be
very useful to reduce the time spent searching for parts and provides a quick
response to quality control.
i.
More value added time by the operators: By the cancellation of nonvalue-adding task of walking a few steps to retrieve parts from flow
racks, now operators stay in a very tight zone and focus nearly
100% of their time on the value-added work of installing parts. The
switch also eliminates reaching, stretching, and searching for parts
by assembly operators. (Value)
35
ii.
Cleaner work areas with visual control: The line become less
cluttered, easier to see, easier to walk around, and just feel like a
much more open work space. (5S)
iii.
Fewer part selection errors: The big advantage of the new material
handling system is simplicity and quality improvement through error
avoidance. (Poka-yoke)
iv.
On the other hand, there are two disadvantages which are the increased
manpower by adding kitting personnel and adding or subtracting pickers
incrementally as takt time changed somewhat harder to do. (leaninstituut.nl):
Industries dealing with heavy and bulky parts, such as metal industry, sizes
of the parts are needed to be considered very carefully for kitting. Some large
parts which dont fit into kits should be handled separately. In a pull production
system, these large parts can be pulled individually while the kittable parts are
pulled together as a kit. (Ding & Balakrishnan, 1990)
36
kitted parts. Whenever a kit is emptied, it is refilled by retrieving parts from this
intermediate storage point. Briefly, pulled by kit would give one rhythm of
replenishment while pulled by part would allow different rhythms for various
kitted parts. (Ding & Balakrishnan, 1990)
For a system that works under pull production, storage container sizes
should be compatible with kit sizes. Otherwise, if at any moment the number of
units in the container of a certain part is less than the kit size, that container is
useless for kitting. The determination of the kit size is affected by container
size, material handling and WIP. (Ding & Balakrishnan, 1990)
There are pros and cons of applying SPS. SPS is one of the reasons to
create a simple, slim and easy system for materials supply. With the
synchronized workstation and balancing line, SPS implementation builds high
quality into the product and is able to create a better working environment. The
other reason for introducing SPS to the assembly line in Japan was the
increase in the average age of assembly operators. Therefore, by replacing the
senior operators on the assembly line and letting them select the parts, it is
easier for them to focus on their job. Moreover, assembly operators have to
memorize many job processes each time a different model arrives at the
workstation. Therefore, the implementation of SPS balances the job of
selection and the assembly of parts.
37
The line following robot is the basic concept of autonomous robot. It
programmed to follow a dark line on a white background or vice versa. It
detects turn and deviations and modified the motors appropriately. The
optical sensor is an array of commercially available IR reflective type
sensors.
2.6.1
Theory of IR reflection
In order to move the robot, it must first be able to sense the black line.
The sensing of black line is based on IR reflective law. IR transmitter
produces the input, which consist of a transmitter and receiver. A transmitter
is a diode that operated by sending electromagnetic wave at wavelength in
infrared region and the wave will be reflected by the detection region.
Meanwhile, a receiver is photodiode that can change according to the IR ray
that is absorbed. They are included in a pair of socket in order to reduce
noise due to scattered light.
38
2.6.2
The logic status is 1 for detecting black line and 0 for detecting the white
line. The microcontroller will receive a feedback through the logic status so
that the robot could make decision when encounter a dead end or to move
by adjusting coordination of left motor and right motor.
Description
Straight
39
Description
2.6.3
Arduino
Arduino is a tool for making computers that can sense and control more of
the physical world than a desktop computer. It is an open-source physical
computing platform based on a simple microcontroller board, and a
development environment for writing software for the board. Arduino can be
used to develop interactive objects, taking inputs from a variety of switches
or sensors, and controlling a variety of lights, motors, and other physical
outputs. Arduino projects can be stand-alone, or they can communicate with
software running on computer (e.g. Flash, Processing, MaxMSP.) The
boards can be assembled by hand or purchased preassembled and the
open-source IDE can be downloaded for free.
40
2.6.4
41
42
43
44
CHAPTER 3
METHODOLOGY
3.1 Introduction
The 5 Whys is a technique used in the analyse phase of the Six Sigma. It is a
great Six Sigma tool that does not involve data segmentation, hypothesis
testing, regression or other advanced statistical tools, and in many cases can be
completed without a data collection plan.
45
Very often the ostensible reason for a problem will lead you to another question.
Although this technique is called 5 Whys, you may find that you will need to
ask the question fewer or more times than five before you find the issue related
to a problem.
46
47
3.3 Problems and Solutions
Problem
Solution
2.
3.
4.
Extracted from the Why-Why Analysis, the table above shows the solution
for each problem occurred. Line Follower Robot with Obstacle Avoidance Sensor
was used to tackle the problem of no fixed route and schedule provided and no
automated transportation to supply the parts. This is because when the material
handler supplied manually, the route is unfixed as human tends to take order and
helplessly resisting when it is needed. As example, Operator A is given the task to
transport a fixed number of parts to production line A. As soon as he transferred the
fifth parts, a work station lacking of part which they need it as soon as possible due
to massive defects on multiple products. Thus it requires Operator A to help that
work station first before he can continue with his task.
Parallel with that problem, he will be rushing and working in a very tense
condition. This kind of event eventually affected the morale of the operator himself.
He wont be in the best condition of working. As he needs to drive a motorized cart,
the speed might be in higher speed. It opened up to possibilities of having an
48
accident. Driving in high speed also could cost a defective part. Thus, the invention
of Line Follower Robot with Obstacle Avoidance is a perfect solution to overcome
these kind of problem. The robot will follow a black tape with a fixed speed and
route. It can deliver bento box for the implementation of SPS. It also comes with
obstacle avoidance feature, where it will stop when a barrier or any object moves in
front of the path.
Next is the problem where no proper arrangements of part supply from the
warehouse to the production line. It took a lot of spaces and no proper supply
system to integrate between the schedule and production demand. The solution to
both problems is the implementation of Set Parts Supply.
In Figure 3.1, shows the flow chart of Line Follower Robot with Obstacle
Avoidance to Transport Set Parts Supply System. The project objective is to define
and set before proceeding to another tasks. The proposal was prepared and
submitted hence the confirmation of final project was verified by the supervisor.
49
As the solution concluded, we analyse and develop the problem using a few
methods such as Ishikawa Diagram, Why-Why Analysis, SMART Table and data
history of the problem.
After that the development of Line Follower Robot with Obstacle Avoidance
starts by drafting design and proceed after the approval of supervisor. Discussion
was made several times to achieve optimum and efficient design. Henceforth, the
approved design was carried for further processes.
Finally, Line Follower Robot with Obstacle Avoidance was put into a test to
validate and verify the functionality of the robot. Once successful, the project is
finally completed and tested.
50
Start
Research and Background Study
Project Selection and Definition
Concentrated on QCDMS
Brainstorming
Project Execution
NG
Material Preparation
Fabricate prototype
Improvement Verification
-
51
3.5 List of Materials
Table 3.3 shows all the list of materials used in succeeding the project.
Table 3.3: List of Materials
Num.
Name of Material
Arduino Uno
Picture
Descriptions
Used microcontroller board
based on the ATmega328P
(datasheet).
It has 14 digital input/output
pins :
6 PMW Digital I/O Pins
6 Analog Input Pins
1 Power Pin
1 USB Connection
Can be simply connect it to a
computer with a USB cable
or power it with a AC-to-DC
adapter or battery to get
started.
Operating voltage : 5V
Flash memory of 32 KB
SRAM : 2 KB
EEPROM : 1 KB
Weight : 25g
2Amp Motor
Driver Shield
Logic
control,
5V
from
protection
for
52
26VDC
(External
Power
Source)
Up to 2A current each channel
Pin 4, 5,6,7 are used to drive
two DC motor
Support PWM speed control
Support advance speed control
Socket
for
LSS05
Auto-
LSS-05
5V power
5 digital output representing
logic of 5 IR sensor
1 press to start calibration
2 press to toggle logic into Dark
On mode, to sense dark line
3 press to toggle logic into
Bright On mode, to sense bright
line
Calibration button for easy of
calibration
Combine with MC40A for line
following robot development
HC-SR04
53
SPG 50 DC
Motors
DC12V
Sample Application:
lightweight mechanism
such as: bank note
machine, handling
machine, educational
robot, etc
Lithium Battery
Fully-charge Voltage:
12.6V
Capacity: 2200mAh
54
3.6 Fabricating Production Model Sample of SPS Implementation
Robot Lane
Conveyor Line
Workstation
Line Follower
Robot with
Obstacle
Avoidance
55
3.7 Function main()
Start
NO
Is tape detected
YES
Move straight
NO
YES
Stop
Dead end
NO
YES
Obstacle in front
NO
YES
Left Junction
Turn
Left
NO
YES
Right Junction
Turn
Right
56
Refer to the Figure 3.3, it can be seen that the program started by waiting command
through detecting black line. It is the input by user, when the line detected, logic
state 0 would be returned to the algorithm and robot is turned on. The logic state of
button 1 is monitored by looping.
The robot will then move straight slightly. A function straight() would be
called in the main program. The sub function is to read the 5 bits number from
LSS05 sensor so that the Arduino Uno microcontroller can process the information
and the robot can make different movement.
After that, the main program would determine type of curve based on input
by line sensor, if the path is a dead end, the robot will stop. If a left curve is
detected, the robot would turn left. If a right curve is detected, the robot would turn
right. If an obstacle is detected, the robot will stop.
57
58
Through Figure 3.4, the straight() function is called to enable robot to
move straight. The function started setting the variable straight flag equals to
1. After that, the condition is checked whether straight flag is less than or
equals to 1. If straight flag is higher than 1, the function straight() would be
terminated immediately. The presence of obstacle would be detected by
parameter in the main algorithm as stated in figure. If obstacle is present, the
function straight() would be terminated immediately. This is to ensure the
robot would not bump onto the obstacle.
If obstacle is not there, the program will start taking reading from
LSS05 5 bit line sensor. If the reading detected is 11111, 01110, 11100 and
00111, the robot move forward to determine the type of path encountered.
When robot moves along the line and encounters a left curve, the
changes of logic status are from 00100 to 01100/11100 for that case. These
readings are sensed by readsensor() function and the data is recorded in
variable s1,s2,s3,s4 and s5. This is indicated as Figure.
void readsensor()
{
s1=digitalRead(9);
s2=digitalRead(10);
s3=digitalRead(11);
s4=digitalRead(12);
s5=digitalRead(13);
}
59
If no curve path is encountered and there is no obstacle, left motor and right
motor would turn based on the position of the robot. If robot is at the centre of
straight line, left motor and right motor would be turned at the same speed. This is
done by generating combinations of PWM signal to left and right motor.
If the robot is slightly shifted to the left, it will allowed to turn slightly faster
than right motor compensate the shifting. So does vice versa. The compensation
would help robot to stay at the centre of line and move forward.
60
61
In Figure 3.5, function turnleft() is nonetheless equal to the movement of the
robot when turning to the right. The function start by setting variable equals to 1 and
variable controlleft equals to 0. Them, the condition is checked whether the data
stored in variable controlleft is less than or equals to 1. If it is larger than 1, the
function will be terminated. If data stored in controlleft is less than or equal to 1, the
program would process to the next stage.
3.10
Summary
62
CHAPTER 4
RESULT AND DISCUSSION
4.1 Introduction
In this chapter, the outcome and result from hardware and software
implementation are discussed. These outcomes included the specifications of the
built hardware and the performance of the robot.
The line follower robot with obstacle avoidance is built of hallow steel body and
two wheels front and a metal ball castor at the back. It is actuated by two SPG50XX DC Motors. The isometric view and underneath view are shown in Figure 4.1
and 4.2:
63
Metal Castor
Wheels
DC Motors
LSS05
64
Specifications
LSS05 Auto-Calibrate Line Sensor
HC-SR04 Ultrasonic Ranging
Sensor
Output
Length
Width
4.3
40 cm
51 cm
In this section, it is about step by step of completing Line Follower Robot with
Obstacle Avoidance. It consisted of a few parts of coding and assembling
processes.
65
https://www.arduino.cc/en/Main/Software
66
Step 3: Open the installed Arduino software and start a new sketch.(Figure 4.4 and
4.5)
67
Step 4: Go to Tools Choose the right board which is Arduino Uno (depends on
what board you are using make sure the Port also connected. (Figure 4.6,4.7 and
4.8)
68
69
Step 6: Upload the Sketch to Arduino Board (Figure 4.10 and 4.11)
4.3.2
Arduino to DC Motors
Both SPG 50 have two external terminals; positive and negative. This
functioned to connect the motor speed by generating the motor to move the
wheels accordingly. The connection from DC motors will then connected to
70
2Amp Motor Driver Shield. It has 6 terminals and will be connected as shown
in Figure 4.12 and Figure 4.13:
MOTOR 1
MOTOR 2
PWRIN
4.3.3
71
4.3.4
The power source also has to be included as, VCC connected to 5V while
GND from HC-SR04 to GND pin at Arduino.
In the setup() function, trigPin stated as output because it will trigger the
wave while echo as input.
72
pinMode (trigPin, OUTPUT);
pinMode (echoPin, INPUT);
Finally the distance was in the prior command, if disruption detected less
than 10cm the robot will automatically stopped. If obstacle in front longer than
10cm, the robot would move according to the coding inserted to LSS05.
73
4.3.5
Figure 4.16 shown the connection of Arduino Uno with LSS05 which is an auto
calibrating line sensor. It used as a sensor to detect black line.
First to make sure the line sensor works, declare the sensors pin to Arduino
Board.
The most left IR named as LeftSen, middle left is LeftMSen, middle sensor is
MidSen, middle right is RightMSen and the most right is RightSen.
In setup() function, all the sensors accounted as an Input as it gives command for
further action.
pinMode(LeftSen,INPUT);
pinMode(LeftMSen,INPUT);
pinMode(MidSen,INPUT);
pinMode(RightMSen,INPUT);
pinMode(RightSen,INPUT);
74
While in loop() function, it would follow Ultrasonic distance direction, it also
accept commands such if 1 it means the IR is receiving input while 0 for the vice
versa. (Refer Appendix E)
4.4
Circuitry
The
circuitry
consisted
of
three
different
modules;
Arduino
Uno
microcontroller main module, motor control module and the sensor input module.
The module are labelled in Figure 4.17:
75
Power Supply
Motor Driver
HC-SR04
LSS05
Arduino
Uno
microcontroller
module
consisted
of
Arduino
Uno
microcontroller, three push buttons, 2 light emitting diode and 2-pin male header.
It acted as a processing unit to store information and generate PWM signal to
drive SPG 50. 2 push bottons are connected and a pun used as on/off switch by
user. One button is connected to the Reset pin of Arduino as an external reset
button. 2-pin male header is used to connect Lipo battery to supply voltage.
The second module is the motor driver module. The function is to actuate the
motor based on signal generated by Arduino Uno. It enabled the motor to rotate
at different angular speed and in both clockwise and anticlockwise direction.
The third module is the sensor module. It provide input to the Arduino Uno
microcontroller. It consists of LSS05 line sensor and HC-SR04 ultrasonic sensor.
LSS05 is connected to the pin A1, A2, A3 and A5. HC-SR04s trigger pin
connected to pin 13 while echo connected to pin 12 using jumper wires. It is
shown in Figure 4.18 and 4.19:
76
77
4.5
Testing
I.
Prototype route
II.
III.
The route constructed using black tape and a few papers. The route is
constructed in a smaller grid multiply smaller than the real size production line.
Its to test the line following capability, robot effectiveness in detecting obstacle
and robot endurance when working repetitively. The distance and length of the
route as shown in Figure 4.20 and the real view as shown in Figure 4.21:
110cm
90cm
78
4.5.2
The line following capability is very important for robot especially when the
input is digital input of 5 bit. The capability must be perfectly tuned before it is
given the ability to reach a predefined destination.
The field for testing the line capability is a rounded rectangular structure. In
this experiment the robot allowed to move on the path and time is recorded. The
experiment is repeated for 10 times and data is recorded in Table 4.2
79
Num.
Time (second)
1.59
1.38
1.41
1.38
1.40
1.43
1.39
1.37
1.39
10
1.36
80
Data analysis by Microsoft Excel and recorded in Table 4.3
1.41
1.992
1.411
From Table 4.3, it can be seen that robot need average of 21.72 second to
travel the field. It achieved variance of 1.992 and standard deviation of 1.411.
4.5.3
The field for testing obstruction is a straight line. The experiment tested the
obstacle detection ability of the robot. In this experiment, the robot is placed at
the one end of the track and an obstruction is placed at the other end. As the
mobile robot followed the black line, it stopped as soon the obstacle is detected.
The distance between the front end of ultrasonic sensor and obstacle is
recorded. The experiment is repeated 10 times and data is recorded in Table 4.4
81
100cm
Distance (cm)
8.5
10
10
10
10
9.5
82
9
82.25
9.070
From Table 4.5, it can be seen that robot need average 9cm to detect
obstacle in front. It achieved variance of 82.75 and standard deviation of 9.07.
4.6
Table 4.6 shown the total bill of materials bought in order to complete this
project:
Table 4.6: Bill of Materials
Num.
1
2
Name of Material
Arduino Uno
2Amp Motor Driver
Shield
LSS-05
HC-SR04
DC Geared Motor
SPG 50
Usable lithium Battery
Jumper Wire Set
- Male to Male
- Female to Female
- Male to Female
Unit
1
1
Price(RM)
62.30
42.00
1
1
2
55.00
10.00
58.00
1
1
20.00
10.
Planetary Geared
Motor Bracket
Nylon wheel
5.90
11.
Iron Plate
2.00
12.
Hollow Steel
12.00
13.
Iron Tray
14.
Paint Spray
7.00
15.
20
0.20
3
4
6
7
8.
9.
TOTAL
RM348.00
83
4.7
Further Discussion
4.7.1
Risk Analysis
Table 4.7 shows the risk analysis of the product in future implementation:
Type of Risk
Risk Ranking
Remarks
1.
Low
Not applicable
Medium
Upgrade motor
product
2.
driver, battery
and motor
3.
Low
Not applicable
Low
Achieve
manufacturing technique
new to industry
4.
84
4.7.2
Table 4.8 shows the corrective action analysis as we faced a few difficulties
and circumstances that need any correction:
Corrective Action
Date Start
Date End
24/6/2015
24/6/2015
9/7/2015
10/7/2015
13/7/2015
15/7/2015
11/7/2015
12/7/2015
2/7/2015
3/7/2015
25/6/2015
25/6/2015
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4.7.3
4.7.4
i.
ii.
iii.
iv.
v.
vi.
Figure 4. 24 shows the current supply system SPS at where the case study
location.
bin to Line
86
Figure 4.25 shows the route of material handling at production before and
after the implementation of the robot.
87
CHAPTER 5
CONCLUSION AND RECOMMENDATION
5.1 Introduction
5.2 Conclusion
The objectives of this project are to study the existing material handling system
and analyse Set Parts Supply system, design and create a prototype of line follower
robot with obstacle avoidance to transport bento box and fabricate the small model
of production line for better understanding about the SPS flow.
88
As a conclusion, the objectives of this project are fulfilled. A production model
was successfully created with a new route of material handling. It also equipped with
the SPS system that have it own racking and kitting box.
We also get a better understanding in the fundamental and specific information
regarding Set Parts Supply throughout the study. Enhaced with the experience of
handling the implementation of SPS itself at the internship placement.
A low cost robot prototype which is able to reach predefined destination by
detecting black line and enhance it with instant obstacle detection ability is designed
and constructed successfully.The implementation of Arduino Uno microcontroller in
the embedded system is able to further increase the line following capability of robot
by generating PWM signal to drive motor. The difference in duty cycle of PWM
signal supply to left and right motor could be controlled in a more precise manner by
using analogWrite() function in Arduino library. This is very important in improving
the line following capability of robot especially to realize the control of DC motor
using software algorithm. The implementation of ultrasonic distance sensor enabled
detection of obstacle and this input is feedback to Arduino Uno microcontroller. This
enhanced the robot with intelligence to avoid obstacle by stop. In the software
implementation, algorithm are constructed based on line following, path and
obstacle detecting. The input is stored and processed by Arduino Uno
microcontroller. PWM signal is generated and supplied to DC motors. The robot is
able to make different movement based on PWM signal generated by
microcontroller
5.3 Recommendation
In this project, there are still improvements to be made in order to increase the
performance of the mobile robot. A few suggestions are provided for future
development.
89
5.3.1 Actuator
The actuator used in this project is SPG 50 due to low cost design statement. For
future development, the SPG 50 could be replaced with actuator with better
transient and steady state response such as stepper motor or brushless DC motor
with higher power to increase the performance of robot.
In this project, one HC-SR04 ultrasonic sensor is used. This enable it to detect
obstacle in front of it. For future development, additional sensor at the blind side
would be helpful as it can detect obstacle in many ways thus lead to a better
detection.
The implementation of Set Parts Supply generally focused from the warehouse to
the production line. The fundamental is supply which comes from the warehouse
itself. Current project targeted to improve the material handling method to
automation supply. For further development, it may improve the storage system and
operation management of Set Parts Supply.