Customer Success at Toyota from Rockwell Automation UK

18 Мар 2015 | Author: | No comments yet »
Toyota Project Go

Toyota press shop system enjoys far greater thanks to lateral thinking

Automation Solution Partner AND designs and deploys robust, solution to replace legacy system


It was companies Toyota who originally defined and just-in-time manufacturing philosophies, components and body panels turn up on the line precisely needed. Although this is an efficient way of doing things – in of time, stock holding and estate – it does place an burden on downstream processes, as the in time (JIT) chain is as strong as its weakest link.

coupled to 24/7 manufacturing, presents maintenance departments a real challenge. The only downtime available to them is the two-week summer shutdown; so all engineering projects have to be in a very small window to full manufacturing starting up

At Toyota’s vehicle plant in Derbyshire, one major engineering – the refurbishment of AGVs that the presses at the beginning of the production – was identified as one that could serious implications in case of a Originally classified as a refurbishment, a change in manufacturing priorities due to the new and Avensis models immediately it to a critical level. but with a short window of opportunity.

However, thanks to lateral by Rockwell Automation Solution AND Automation, coupled to Toyota’s to entertain alternative technologies, the was solved quickly and with a Automation-based solution that a far simpler and more effective path.


The AGVs back and forth between different locations, two sides of the the stacker and the de-stacker. Stuart Press Engineer, Press and Division, at Toyota explains: The AGV originally comprised eight and was subject to a number of upgrades the years, with units and systems being removed and Last year we were with just one remaining vehicle, but the infrastructure was for eight and was and hard to look after; it was a liability.

As the press was not running all the it was originally decided that refurbishment would suffice, continues. However, an upturn in meant that the press be in far greater demand and indeed a press would come operation. The refurbishment was replaced by the for a completely new system. one that had to be quickly and then installed the summer shut down.

Toyota had to find someone who provide the new system within the budget and subsequently contacted AGV/RGV manufacturers along numerous automation and control One such specialist was AND Automation, who had used before. AND Automation up with the suggestion for a rail-guided which not only offered and simplicity but, just as could be designed and installed on and within the restricted time

AND Automation showed us the company would be providing the hardware, explains. We were impressed the robustness. Everything in a press has to be robust as it all gets an absolute


Tony Brooks, Director at AND Automation, explains the his company developed: The existing infrastructure was driven by an Allen-Bradley which meant that of a new contemporary solution from Automation would be far simpler. was also happy with its equipment and therefore the learning was shallower.

The new control solution deployed to the rail-guided trolley cars has an CompactGuardLogix® programmable automation (PAC) at its heart. Communications to all devices and to various I/O points, safety and non-safety Point are via EtherNet/IP. Each trolley car has controls, I/O, safety I/O and intelligence to look at and react to targets on walls and machines. The panel, which houses the power distribution and I/O, remote panels which Allen-Bradley PowerFlex® drives positional control), safety I/O and I/O for all cars. A PowerFlex 753 is used for position control of the main while a PowerFlex 4 is used for the bed conveyors on the trolley cars. The which run over EtherNet/IP, deploy safe torque-off Completing the primary components is an PanelView™ HMI on the door of main to provide full diagnostics, set up, and alarms.

The safety solution a fence line with entry points. These points interface with the solutions on other machines and can multiple, changing zones on where the operator enters. The PAC allows Toyota to deploy safety, which is programmed than hard wired. As a clever monitoring of the trolley creates multiple dynamic zones, giving the customer flexibility.

We don’t have any other solutions apart from one, so to us it was new. It is doing a job. We have had a few minor issues mainly down to the comms method, but AND Automation has able to mimic the old comms but on much more up-to-date The up time is very, very far better than the old system.

Brosnan, Section Manager, Department at Toyota, discusses the from a purchasing perspective: as a business, when we are looking to equipment we work with the department to develop a specification and go out to market. This project this way – we knew we wanted to or replace. The great thing is we have the flexibility to accept suggestions; we are open to other

When AND Automation came to us, Brosnan continues, rather adhering tightly to the specification we realised that there be a different technology that achieve the same result. To us it was – challenging a tried and tested We had no comparison, but commercially it made and we wanted the press shop to buy in to the

We continue to enjoy an open-book with AND Automation, she concludes, openly discuss with us how reached the solution and a meeting their suppliers eventually led to the of a project team. As the project we needed to refine the new spec – by AND Automation, who took purchasing with them, rather just being at the start and We were there all the way through – we mould decision making From a procurement point of you often hear of companies who say is an exercise, here is the spec. and company has not met the spec therefore out. We, on the other hand, are to entertain alternatives.


A Rockwell Automation was installed, which included:


Point I/O

Allen-Bradley 753

Allen-Bradley PowerFlex 4

Allen-Bradley HMI

Far greater up time

In time and on

Extremely robust

Clearer path

Open communications

Allen-Bradley, CompactGuardLogix, PanelView, and Point I/O are trademarks of Rockwell Inc. Trademarks not belonging to Automation are property of their companies.

Toyota Project Go
Toyota Project Go

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