Automobile final assembly is the process of assembling various components of a car together, and it is the place where the entire car can be seen throughout the entire manufacturing process.The planning of a high tempo assembly line requires the rational planning of the process flow, information flow, and logistics of automobile assembly with intelligent manufacturing thinking, in order to achieve unified, coordinated, advanced, low-cost production, high-quality and rapid delivery of the three flows. "(Hu Changhua, Chief Engineer of the Architecture Development Center of Dongfeng Motor Group Co., Ltd., First level Expert of Dongfeng Motor Corporation, 2022). It is not easy for factories to assemble tens of thousands of components onto vehicles on a flexible assembly line. Moreover, a final assembly line may have two or even more vehicle models simultaneously. So how is the final assembly process completed?

From the perspective of factory layout, the final assembly workshop is independent and complex. The area of the final assembly workshop is much larger than other workshops, ranging from tens of thousands of square meters to tens of thousands of square meters; In terms of the number of workers, the final assembly workshop also far exceeds other workshops, with more than half of the workers in a car factory working in the final assembly workshop. Meanwhile, the final assembly workshop is relatively independent: for example, the stamping, welding, and painting workshops provide the body, while the component suppliers provide the parts. This type of assembly line consists of a main line and a sub assembly line, and each production line has multiple workstations, each responsible for a different process.

The production cycle time is the most important indicator for measuring final assembly, that is, the shorter the interval between the production of two adjacent vehicles, the higher the production efficiency. Therefore, how to match JIT (Just in Time) with the debugging of base workstations and processes, the process layout of each line, and the supply and transportation of spare parts for each line“Deliver according to the operating rhythm of the production line”The operation mode and transportation method directly affect the efficiency of the final assembly workshop. Toyota was the first to invent the SPS mode. The SPS (Set Parts System) is mainly aimed at the assembly lines in the automotive industry, where each launch is a quantity. A quantity may be 10 cars, it may be 12 cars. The installer only needs to obtain the parts in order within this quantity, making their work relatively simple and efficient.

It is worth noting that if the supply of any link in SPS mode cannot keep up, the final assembly workshop will stop working.

Therefore, the high tempo assembly line requires us to carry out a comprehensive and intelligent system planning for process flow, information flow, and logistics. This article focuses on the intelligent wireless PTL (Pick to light) light picking system launched by Afadi Intelligent IoT, which achieves material picking in the SPS picking area through wireless PTL electronic tag on/off indication, and improves efficiency from the following three points:

• Prevent picking errors or omissions in the SPS picking area and achieve electronic picking;

• The wireless PTL electronic tag picking terminal can cooperate with photoelectric sensing and wristbands to automatically turn off the lights, without unnecessary pressing or pulling actions, reducing the complexity of employee work;

• Improve the accuracy of picking through system instructions.

Aurora Cloud™Wireless PTL solution:

The first step is to create a new warehouse location and material relationship process

Step 2: restocking and warehousing - minimum inventory warning pull&production task pull:

Step 3: Pick and dispense from the warehouse

SPSCar+electronic ink screen replaces traditional paper picking list solution:

More options:

Wireless PTL line edge hardware intelligent management

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Aurora Cloud™ Wireless PTL photosensitive picking terminal

Technical features:

1. Adopt industrialized wide voltage (industrial 12V~30V) DC power supply, lightning protection and impact resistance. Design 3 sets of status indicator lights, making the equipment's working status clear at a glance, quickly determining the cause of faults, and easy to maintain

① Pow: Green, indicates the power status indicator light, and the green amount indicates that the power is normal

② R/T: red green dual color, communication status indicator light, flashing indicates normal communication

2. Fast data refresh rate, millisecond level refresh rate, far higher than the refresh rate of ink screens

3. LED lighting components have a lifespan of over 100000 hours

4. High strength aluminum alloy guide rail design, resistant to damage and impact from shelf deformation or external forces on equipment

Aurora Cloud™ Wireless PTL photosensitive picking terminal system architecture