MINISTRY OF EDUCATION AND TRAINING HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY FOR HIGH QUALITY TRAINING GRADUATION PROJECT MECHATRONICS ENGINEERING IMPLEMENTATION & DEPLOYMENT OF AN INTERLOCKING SYSTEM TO CONTROL PROCESS ROBUSTNESS FOR SCHNEIDER ELECTRIC MANUFACTRING VIETNAM ADVISOR: DR. DANG TRI DUNG STUDENT: AN THANH TUNG SKL009893 Chi Minh city, August 2022 HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY OF HIGH-QUALITY TRAINING GRADUATION PROJECT IMPLEMENTATION & DEPLOYMENT OF AN INTERLOCKING SYSTEM TO CONTROL PROCESS ROBUSTNESS FOR SCHNEIDER ELECTRIC MANUFACTURING VIETNAM Student Name: AN THANH TÙNG Student ID: 18142073 Major: MECHATRONICS ENGINEERING Advisor: ĐẶNG TRÍ DŨNG, PhD. Ho Chi Minh City, August 2022 HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY OF HIGH-QUALITY TRAINING GRADUATION PROJECT IMPLEMENTATION & DEPLOYMENT OF AN INTERLOCKING SYSTEM TO CONTROL PROCESS ROBUSTNESS FOR SCHNEIDER ELECTRIC MANUFACTURING VIETNAM Student Name: AN THANH TÙNG Student ID: 18142073 Major: MECHATRONICS ENGINEERING Advisor: ĐẶNG TRÍ DŨNG, PhD. Ho Chi Minh City, August 2022 i THE SOCIALIST REPUBLIC OF VIETNAM Independence – Freedom– Happiness -------- Ho Chi Minh City, August 31st, 2022 GRADUATION PROJECT ASSIGNMENT Student name: An Thanh Tung Student ID: 18142073 Major: Mechatronics in Engineering Class: 18146CLA2 Advisor: Dang Tri Dung, PhD.
Phone number: 0969810740 Date of assignment: 07/09/2022 Date of submission: 18/02/2023 1. Project title: IMPLEMENTATION & DEPLOYMENT OF AN INTERLOCKING SYSTEM TO CONTROL PROCESS ROBUSTNESS FOR SCHNEIDER ELECTRIC MANUFACTURING VIETNAM USING WINDOWS FORM APPLICATION COMMUNICATION WITH PLC M221. Initial materials provided by the advisor: Plant database (Work orders, quantity, schedule) Product Database (Product references, label templates, process flow diagrams). Using Visual Studio Windows Form Application.
Using Microsoft SQL Server Software. Using EcoStruxure Machine Expert – Basic Software. Content of the project: Build label database for the using references. Create UI using the windows form application.
Modify the PLC program on usage devices suitable with the new UI. Trial Run → Debug → Training → Live Run. Final product: Windows Form Application is used for managing manufacturing activities. Improve the process of product references to prevent bypass during operation time.
Create historical data for each product for easy tracking. Compilation thesis report. ii THE SOCIALIST REPUBLIC OF VIETNAM Independence – Freedom– Happiness -------- Ho Chi Minh City, August 31st, 2022 ADVISOR’S EVALUATION SHEET Student name: An Thanh Tung Student’s ID: 18142073 Major: Mechatronics in Engineering Project title: IMPLEMENTATION & DEPLOYMENT OF AN INTERLOCKING SYSTEM TO CONTROL PROCESS ROBUSTNESS FOR SCHNEIDER ELECTRIC MANUFACTURING VIETNAM USING WINDOWS FORM APPLICATION COMMUNICATION WITH PLC M221. Advisor: Dang Tri Dung, PhD.
Content of the project. Approval for oral defense? .) Ho Chi Minh City, Day., 2023 REVIEWER (Sign with full name) iii THE SOCIALIST REPUBLIC OF VIETNAM Independence – Freedom– Happiness -------- Ho Chi Minh City, August 31st, 2022 PRE-DEFENSE EVALUATION SHEET Student name: An Thanh Tung Student’s ID: 18142073 Major: Mechatronics in Engineering Project title: IMPLEMENTATION & DEPLOYMENT OF AN INTERLOCKING SYSTEM TO CONTROL PROCESS ROBUSTNESS FOR SCHNEIDER ELECTRIC MANUFACTURING VIETNAM USING WINDOWS FORM APPLICATION COMMUNICATION WITH PLC M221. Name of Reviewer: Tran Thuy Uyen Phuong PhD. Content of the project.
Approval for oral defense? .) Ho Chi Minh City, Day., 2023 REVIEWER (Sign with full name) iv ACKNOWLEDGEMENT First of all, I would like to express my deep gratitude to my advisor, Dr. Dang Tri Dung, who guided me throughout the process of writing my project, for his insights and useful advice. His extensive knowledge, willingness, and commitment have truly inspired me to keep learning with all my passion. Although my topic is not too related to your expertise, you can still give me advice and direction in the project process as well as corrections and suggestions for my report.
Secondly, I would like to express my deep gratitude to the HCMC University of Technology and Education teachers for their dedication to imparting solid professional knowledge to students, which has helped me finish this project. This project is a consolidation of my four-year knowledge gained from courses delivered by dedicated faculty. In addition, I would like to especially thank the Schneider Electric team for their support during the project, both in terms of hardware and software, and the necessary equipment for the smooth operation of the system. The Interlocking system is the result of the cooperation of all departments of the company, notwithstanding the contributions from the operators, who directly work with equipment that can come up with common failures mode.
v ABSTRACT Schneider Electric Manufacturing Vietnam is an expert in manufacturing switches and sockets with over 120 production lines but mostly are using manual process. In recent years, SEMV has received many negative feedbacks from customers about (Product’s failed functions, missing components, not fully packaged, etc. Despite the company has released OWS (Operation Work Standard) or using tester at each station to prevent error. However, it is not the optimal way to control these failure modes.
Faced with the above problems, we discussed and found a solution that guides the workers’ operation and ensures that the processes are executed sequentially and cannot be skipped - the Interlocking System. This system will combine with the current auto label printing system – Traceability- which will automatically generate a QR label. The goals of this system should include upgrades of current hardware (upgrading QC testing machine, suitable hardware installation), data acquisition (product historical data, the condition of each product, tracing back the source of errors, production order), and compatibility (application for communication between hardware and database, general application platform to be applied to multiple production lines, establish communication between hardware and database). After a trial run and evaluation period, the system proved to be accurate, efficient, and coherent.
At the same time, create trust from customers and enhance SEMV's reputation. However, this system remains some open points: lack of small components during assembly that cannot be detected by the testers, cannot detect the included accessories due to the error of the scale, increased cycle time, and still quite new to the workers resulting in them not adapting to the system. By accepting that all failure modes cannot be controlled, this system has successfully reduced the RPN score and cycle time, fixed many of the early problems, and allowed live runs. We are heading to apply for more lines & come up with new solutions to further improve this system.
Keywords: Manual process, Interlocking system, PLC, historical data, QR label, compatibility, control failure mode, skip processes, RPN score, cycle time. vi TABLE OF CONTENT ACKNOWLEDGEMENT. vi LIST OF TABLES. x LIST OF FIGURES.
xi Chapter 1 : INTRODUCTION.1 Project background & Problem Statement.2 Solution for the current situation of SEMV .3 Objective and Research Method .4 Scope and Limitations .1 Scope of the project. 7 Chapter 2 : LITERATURE REVIEW .1 Theory of Interlocking .1 Windows Form Application Programming .2 Modbus TCP/IP protocol .4 SQL Server Management Studio (SSMS) .5 EcoStruxure Machine Expert Basic [19] .3 Currently process control application in SEMV .1 Iconic Packing Application .3 Poka-Yoke Packaging .4 Failure mode and effects analysis (FMEA) [21] .5 Ergonomic workbench systems for industrial & commercial use. 27 Chapter 3 : DESIGN AND IMPLEMENTATION .1 System Overall Block diagram .3 System Operational Description .2 Electrical block diagram .3 Electrical cabinet design .4 Printing Application Design .1 Overall architecture application .5 Printing Application Interface .5 Testing Application Design .1 Overall Architecture Application .5 Testing Application Interface .1 Overall Architecture Application .5 Packing Application Interface. 73 Chapter 4 : EXPERIMENTAL, ANALYSIS, SUMMARY RESULTS .2 Data collection/Experiment implementation.
81 Chapter 5 : CONCLUSION, IMPROVEMENT, FUTURE PLAN, AND RECOMMENDATION .4 Release Data Letter. 86 ix LIST OF TABLES Table 1: Pin Description DB-9 Connector. 14 Table 2: Pros and Cons of SSMS. 17 Table 3: Schneider Electric Manufacturing Vietnam’s RPN score rate.
25 Table 4: Devices used in the Interlocking System. 30 Table 5: Devices used in the electrical block diagram. 36 Table 6: Proposal for a new design of traceability label. 43 Table 7: Function of the First station.
46 Table 8: Function of the testing station. 58 Table 9: Function of Packaging Station. 68 Table 10: Establish metrics and units. 74 Table 11: Link metrics to needs.
75 Table 12: Assign marginal and ideal values. 75 Table 13: Table methods of experiments. 76 Table 14: RPN Analysis for bypass testing. 77 Table 15: RPN Analysis for the missing package.
78 Table 16: RPN Analysis for the wrong label. 78 Table 17: RPN Analysis for wrong week-code. 78 Table 18: Test Criteria. 80 Table 19: Finalize specification.
81 x LIST OF FIGURES Figure 1: Layout of SEMV Plant [24]. 1 Figure 2: Overview of some of the company’s products [24]. 1 Figure 3: Mass pre-printed labels. 2 Figure 4: Missing package (example).
2 Figure 5: Example of wrong label pasting. 2 Figure 6: Iconic Assembly + Packaging Line. 3 Figure 7: Layout transformation. 4 Figure 8: Workflow transformation.
4 Figure 9: Graphical conventions used to illustrate networks .11 Figure 10: Autonomous System (AS) mapping .11 Figure 11: Network and internet addresses .12 Figure 12: RS232 protocol .13 Figure 13: RS232 or DB9 male connector .14 Figure 14: RS232 or DB9 female connector .14 Figure 15: Application Interface.20 Figure 16: Overall station layout .21 Figure 17: Concept of system .21 Figure 18: Application Interface.22 Figure 19: Overall station layout .22 Figure 20: Concept of system operation .23 Figure 21: Poka-Yoke Packaging Interface .23 Figure 22: Overall station layout .23 Figure 23: Example workbench .28 Figure 24: Example workbench system .29 Figure 25: Interlocking System Connection Diagram .32 Figure 26: Interlocking Process Overall Diagram .32 Figure 27: Anthropometric analyses [22] .34 Figure 28: Top view working zone [22] .34 Figure 29: Operator’s working zone [22] .35 Figure 30: Printer setup for easy operation .35 Figure 31: Electrical block diagram .37 Figure 32: Electrical cabinet circuit schematic.38 Figure 33: Printing architecture application .39 Figure 34: Table itl_view_WO .40 Figure 35: Load Data for Printing Station code .40 Figure 36: Code result in SSMS & explanation .40 Figure 37: Code result when assuming choosing line A01_FG .41 Figure 38: Table itl_printing_header .41 Figure 39: Zebra Setup Utilities Interface .42 Figure 40: Online viewer website (Labelary.42 Figure 41: ZPL code logic .43 Figure 42: QR labels from Printing Station .44 Figure 43: Databases use for information transfer .44 xi Figure 44: Communicate diagram .45 Figure 45: Login form of the first station .45 Figure 46: UI design of the first station.46 Figure 47: UI of first station .47 Figure 48: Calibration button interface .47 Figure 49: Print Manual Interface .48 Figure 50: Print Manual Login Interface .48 Figure 51: Input Print Quantity Interface .49 Figure 52: Successful printed pop-up notification .49 Figure 53: Printing System Process Flowchart .49 Figure 54: Printing station flowchart .50 Figure 55: Testing architecture application .51 Figure 56: SEMV’s Tester .52 Figure 57: Table itl_master_dummy_data .52 Figure 58: table itl_master_tester_data.53 Figure 59: Table itl_master_testing_result_history .53 Figure 60: Demonstrate database operation .54 Figure 61: Database alignment with PLC IP (E83426-T01) .54 Figure 62: Change Ethernet TCP/IP to the same layer with PLC .54 Figure 63: Connecting Method .55 Figure 64: Digital Inputs .55 Figure 65: Digital Outputs .55 Figure 66: Interlocking signal in the PLC program .56 Figure 67: Pass and Fail conditional .56 Figure 68: Pulse signal for counting bits .56 Figure 69: Memory word used for counting bits .57 Figure 70: Communicate diagram .57 Figure 71: Login form of the testing station .57 Figure 72: UI of testing station .58 Figure 73: SQL database before update .59 Figure 74: SQL database after update .59 Figure 75: Testing System Flowchart.60 Figure 76: Testing Process Flowchart .60 Figure 77: Packing architecture application .61 Figure 78: Table itl_packing .62 Figure 79: Table itl_standard_weight .62 Figure 80: Table itl_packing_history .63 Figure 81: Database connection .63 Figure 82: Connection between database and template directory .63 Figure 83: Zebra Setup Utilities UI .