GPME Controls Strategy

Best In The World

afety

SOS
Programma
ble Safety
Systems
Simplified
Lockout
Policy

uality

QOS
Flexible
Manual
Inspection
Standardiz
ed Quality
Reports

elivery

ost

eopl
e

DOS

COS

Production
Scheduling
Smart
AutoCall
Complexity
Manageme
nt
45 Day
Launch

Lower Total
Life Cycle
Costs
2+1
BoD/BoP
Flexibility
Enabler

POS

are
w
t
f
So

Training
Course
Execution
Common
Operator
Interfaces

MOS

EOS

Remote
Expert
Assistance
Standardiz
ed
Constraint
Manageme
nt
Diagnostics

Energy
Data
Collection
Energy
Manageme
nt

Stra
tegi
e
s

OMS
(RFID)

GPTS
QTS
(QLSCM)

aintenance nvironment

FAS
T

FIS+

Foundational Standards

Distributed Control Hardware

Architectures
Standardized Equipment Naming
Convention
Manufacturing IT Footprint

CPN/MPN Profinet Communication

Networks
Data Collection Definitions
Controls Basket of Goods

Legacy RF Tag Problem Statement

Project Description:

Legacy RF Tag Systems in use by OEM are proprietary solutions

RF Tag Maps are not common across Plants / Programs leading to
significant re-Engineering
Difficult to support Process Changes

Project Objective:
Migrate to Industry ISO RF Tag
Standardize the RF Memory Map across Powertrain
Support All Standard and Exception Process Requirements
Minimize Cost and Timing impact of Process changes
Meet or exceed New Model Launch Process Rate of Climb
Objectives
Reduce long term dependency of RF Tag for Processing a Part

OMS Standard Architecture

RF Tag Map -> 2K footprint (ISO RF Tag)

Part / Pallet Identification
Pallet Management & Routing
Complexity / Recipe Management
Operation and Task Level Status to Support:
Conditions to Cycle
Regression Management
Offline Diagnostics
Build Forward (Exceptions only)
Backup Operation (Exceptions only)
Process Data to Support:
Downstream Operations
Flexible Manual Inspection
Attribute Data for Offline Diagnostics (Exceptions only)

RF Tag Data Legacy Map / OMS Map

Operation Management System

(OMS)

OMS is a configuration tool that generates the RF tag map and

Recipes based on the configuration assigned to Operations.
The configuration includes:
RF tag addresses of the Operation status, Task(s) status(es), and Process
data which are required to be read/written by an operation.
Recipes for each model that is used by the Operation to select correct
Components to be installed and Work Instructions

The configuration is downloadable to all operation PLCs

directly. OMS also generates a file to supply the RBMs with
a decoder of the RF tag map, allowing rebalancing and
reprocessing of the production line minimizing PLC logic
changes.
5

System Architecture - Legacy State

Complexity Table:

Manage
Recipes
Inactive

Decision Point PLC:

OK to proceed determined based on fixed

addressing and custom logic for all
upstream Operations
Birth History information read from RF Tag
and Uploaded to QLSCM

Flow

RF Tag
Reader

Definition Point
PLC:

Complexity Table
loaded to Definition
Point PLC
Definition Point PLC
loads Recipes to RF
Tag

OP
0020
PLC

Decision Point

OP
0030
PLC

Flow

OP
0010
PLC

Transport
TR001
PLC

PLC/HMI
Operations PLCs:

OK to Work determined based on fixed addressing

and custom logic for upstream required Operations
RF Tag Recipe read for Complexity Management
(Components or Work Instructions)
Status updated based on fixed addressing for
Operation
Birth History information written to RF Tag

System Architecture With OMS

OMS:

Decision Point PLC:

Manage Recipes
Manage RF Tag
Addressing
Download Configuration
to Operation PLCs

OK to proceed determined
based on OMS addressing for
all upstream Operations
Birth History information
uploaded to QLSCM via QTS

Flow

RF Tag
Reader

Definition Point
PLC:

OP
0020
PLC

Decision Point

OP
0030
PLC

Flow

OP
0010
PLC

Transport
TR001
PLC

PLC/HMI
Operations PLCs:

OK to Work determined based on OMS addressing

of required upstream Operations
Complexity Management (Components or Work
Instructions) via OMS downloaded Recipes
Status updated based on OMS addressing for
Operation
Birth History information written to QLSCM via QTS

OMS Pre-Requisite Worksheet

(Design Phase)

PTO Equipment Naming Convention

Examples

Operation naming convention shall follow the process

sequence found on the assembly line

Example 1: Assembly line with two working positions

AE.0050.1A

AE.0050.1B
FLOW

Example 2: Assembly line with parallel operations

AT.0060.1A

AT.0060.2A
FLOW

OMS TOOL HIERARCHY

1. Start

2. Config Ops

3. Config Work Positions

4. Config Acceptable Part Numbers

10

OMS Configuration General

(Configure Phase)

Can be a shared responsibility by the Controls and Process Engineers

This is similar in practice to the Complexity Table management but OMS would be
active and eliminates the failure modes associated with transferring the tables to
Definition Point PLCs
11

11

Insert Filename and Rev #

Standard Operator Screen

(Verification Phase)

Definition of a Task

A task is an individual process step that is required in the

assembling of a Powertrain component with associated
status (feedback). When allocating tasks the user should
consider what individual status(es) would be required for;
status indication in the evaluation bay
partial regression to the task level
required for future conditions to cycle at downstream
operations

HMI Diagnostics
OMS OK to Build Screen

CSV file generated from OMS

(used by RBMs)

Reject and Regression Management

Common RF Tag Map Allows:

1. Standard Evaluation Bay Layout & Strategy
2. Process changes entered into OMS provides RBM with file
to decode and display assembly process status
3. Development of 5 Acceptable Regress Levels
4. Standard Approach (hardware and software) to restage the
RF Tag according to completed defect and repairs entered

16

Production Load System

Operator enters desired

Job ID to be modified

Operator selects required

Model-Ship Code
(fed from OMS)

Operator enters
desired build quantity

17

PLS Model & Ship Codes received

from OMS

OMS Supports up to 99 Recipes

Configured Recipes within OMS are automatically displayed on PLS
18

OMS Statistics to Date *

350+ Users trained since 2012

(PTME training week, monthly FAST/OMS Classes, and OEM on-site)

Ford
Total

OMS Configurations to Date

Plants
Lines
Using
OMS
Configured
Recipes

Bordeaux Camacari
Transmission Engine

Sanand
Engine

Chongqing Chongqing Cleveland Lima

Engine Transmission Engine Engine

Sterling
Axle

Van Dyke
Transmission

10

37

35

12

57

11

71

195

Using the OMS files configured to date, there is opportunity to develop

template (engine, transmission) OMS configurations.
* - Note Statistics represent OMS files configured as of October 2013.
Configured OMS files represent programs in design, launch and production.
19

Lessons Learned

Training OEMs, Process, Controls and Plant Engineers

Define an ownership team for OMS configuration files
through all phases of launch (design, deployment, launch)
Configure OMS files early during equipment design phase
Hold OMS configuration reviews with Core team to verify
proper formatting and completeness
Have the OMS plant system ready prior to tooling installation
at assembly facility
Engage plant OMS ownership team early during launch
phase

20

Next Steps/Enhancements

Web Based Configuration Tool

Remove redundant configuration between OMS and QTS
Align RF Tag Maps between Machining and Assembly
Complete with Revision 4.3 (Released Jan 2015)
Automate ability for Evaluation Bay and PLC to request OMS
recipes
Eliminate redundant QualityWorx configuration in
Fastening/Test/Vision systems by using OMS data
Standard Re-Configurable Manual Stations
Preconfigured OMS Template for each Bill of Process

21

Core Engineering Alignment in Strategies

OMS /
RF Tag

Enabler
Common
License
Plate

QT

S
(Q
LS
CM
)

Reject &
Regression
Management

FA
ST

PLS
Line Side
Scheduling

ST
D
Na St
m atio
in
g n

In
du
R stry
F
Ta IS
g O

Ford

Structured
RF Tag

22