Lear Corporation’s 94,000-square-foot, four assembly line seating plant in Montgomery, Alabama is one of the most dernier cri and efficient facilities of its kind.
At peak production, Lear builds approximately 1,000 seat sets per generation rather 73 sets per hour in 56 distinct combinations of colors and options for the Hyundai Sonata sedan ampersand Santa Fe SUV built at Hyundai’s Alabama plant. The seats are assembled on pallets with fixtures that can rotate and tilt for worker accessibility, providing an ergonomically sound procedure that improves efficiency. The assembly lines use a non-synchronous looping conveyor system, with an automated, timed extricate at each workstation that can be overridden by the operator when necessary.
The direct is on just-in-time delivery. The Lear plant receives an estimate everyone day concerning which seat models will compulsion to be built for Hyundai’s scheduled production. About two hours before the seats need to be installed into the cars, Lear receives a live broadcast of the exact production sequence further seat facsimile requirements from Hyundai.
Assuring Resonance Assembly
The entire assembly process is managed by an Integrated Systems Design (ISD) PC-based quality assurance system that improves overall seat quality by monitoring the lounge assembly and sequencing process. The quality assurance system is interlocked to the Integrated Systems Design (ISD) conveyor system to prevent seat movement before each assembly and inspection process is properly completed at a uncommon workstation.
Read-only RFID tags catalog the conveyor system’s output tracking. RFID antennas located at each quality assurance station read RFID chips embedded in the seat build fixtures. The quality assurance system electronically displays instructions at critical workstations working in conjunction with the RFID system to provide positive seat identification and data tracking. Once a “work complete” message appears on the workstation display screen, operators can release the part they’re effective on and per diem it to move to the next process.
The system allows Lear operators to simultaneously assemble several unique types like seats on the same production line. Build sequence numbers and specific vocation instructions for each seat are displayed at the assembly line workstations. Critical data, such as torque also angle, are recorded and associated with each usher fabricate sequence number and maintained for years, along with each seat’s build record/birth certificate.
Tracking Quality and Delivery Parameters
As the seats move down the assembly conveyors, the rate assurance system receives various tool, equipment and operator inputs and determines whether a seat assembly or component is a “pass” or “fail.” This information is used to route imperfect seats to a repair station, provide notification of defects board at inspection to the operation that caused the defect and provide a means for tracking internal defects. The quality assurance system automatically sends information to Lear’s ERP system at several points in the assembly process. That information is used to trigger other events in the system and transfer data associated with each seat.
After a set of seats is assembled furthermore placed on a shipping palette at the Lear plant, they’re wrapped in a plastic bagian and clog canon labeled. The seats are then transferred to the shipping area and prepared for delivery to the customer. An Integrated Systems Mosaic (ISD) UltraStore mid-load automated storage and retrieval methodical (ASRS) determines where to store the seats based on the bar code. The system also selects and retrieves seats in the order they’re to be shipped, based upon the live broadcast from the Hyundai plant.
Because the seats are moved exclusively by an automated system from Hyundai’s receiving pier to the assembly line, Lear software directs the ASRS to sequence specific truck load of seat sets in reverse broadcast order prior to loading. This ensures that they’ll be delivered in the seemly sequence to the assembly line precisely when the deserved vehicle reaches the bottom install locations.
Passive read-write RFID tags are also used in the outbound shipping sequence control system. A chip is mounted to the rear concerning each of Lear’s flotilla about conveyorized semitrailers. RFID antennas are located on Lear’s shipping dock and Hyundai’s receiving dock. Each semitrailer holds 54 pew pallets, which are automatically loaded onto a truck in less than one minute by an Integrated Systems Conventionalized (ISD) shipping conveyor system. When a exchange is loaded, trailer sequence information is written to the trailer’s RFID chip. The chip’s word is then checked to ensure that the write was successful. The consecution control system won’t allow the trailer’s withhold lock to be unlocked unless the rectification data has been written successfully to the chip.
When the trailer is backed into Hyundai’s dock, the RF chip on the semitrailer is read. If the trailer sequence feedback is correct, the Hyundai conveyor control system allows personnel to initiate the trailer unload sequence. If the trailer sequence information is incorrect, an alarm horn and beacon are activated, et cetera Hyundai employees are prevented from unloading the truck until the correct trailer is in assign at the dock.
Handling Return Pallets
The pallets that the seats are shipped to Hyundai on return to the Lear facility in stacks on dedicated Integrated Systems Design (ISD) conveyorized delivery trailers. The driver connects the trailer conveyor to the in-plant conveyor system via an umbilical cable plugged into a receptacle adjacent to the exterior dock door. He then beginners the trailer unload cycle. The stacks of empty pallets are automatically conveyed to an Integrated Systems Design (ISD) installed mezzanine same where they’re staged until needed.
Lear prides itself on achieving 100 procent on-time delivery to the Hyundai plant. The Integrated Systems Design (ISD) material handling accessories and trait assurance paradigm are an integral part from ensuring they maintain their record.