Manufacturing Control Systems for Toshiba

Author(s):
Mark Callahan - Orthstar

Industry:
Consumer Goods

Products:
LabVIEW Datalogging and Supervisory Control Module, LabVIEW

The Challenge:
Creating a customized process control and quality data interface system to network stand-alone pieces of manufacturing equipment, such as PLCs, robots, process machinery, and test stations, on four television picture tube manufacturing lines for Toshiba Display Devices.

The Solution:
Developing and implementing a customized, cost-effective, easily maintained, process control and quality management system using National Instruments LabVIEW Datalogging and Supervisory Control Module.

Since 1974, ORTHSTAR has developed custom systems and software applications for factory automation and process control, railroad and transit, aircraft and aerospace, power generating utilities, and commercial product development. When ORTHSTAR was granted this project, Toshiba Display Devices had already embarked on a $15 million project to improve their existing manufacturing lines and install four new production lines. Toshiba contracted us to develop a system to network the isolated equipment and automate the collection of process data at strategically placed nodes. Accessibility to the nodes containing relevant data would give the Process Engineers, Quality Assurance Engineers, and Production Supervisors the ability to make data-driven decisions related to process control, quality, and production schedules. Because the development portion of the project had been delayed, we only had 16 weeks to complete the code and install the system.

System Requirements
Toshiba would not accept any downtime once we installed the system, and it had to run the first time out. Other fundamental requirements included:

• Access to data directly at the node with touch screens to make decisions on adjusting the processes
• Remote access to the data to obtain production and reject rates for just-in-time deliveries
• Visual confirmation that the nodes were up and running properly
• Continuous operation, 24 hours a day
• Quick and easy system programming, maintenance, and debugging
• Ability to send older data automatically to an AS400 database for permanent storage
  

Toshiba had already chosen LabVIEW as the development language, so we did not need to write a text-heavy design document, as we would with C/C++. They chose LabVIEW for several reasons including:

• Reduced development time versus conventional C/C++ programming - up to 10X faster using LabVIEW
• Fewer resources required to work on the project and maintain the system
• Reduced time to make documentation changes - the code block diagram is the documentation, and ability to debug on-the-fly

The three engineers completed the programming and testing of the four LabVIEW nodes in the 16 weeks allotted. We implemented and debugged the programs for three of the four nodes while technicians from overseas installed the new production lines. No downtime was accumulated at start-up and minimal changes were made while the processes were running.

Each node interfaced with hundreds of individual pieces of manufacturing and test equipment. When combined, the nodes collected and trafficked more than 1,400 data points from these processes. We then converted the data into a structured format, assigned error codes, and stored it in a usable format at each node to make the data available for process control and quality assurance decisions.

The system also tracks each picture tube individually via a bar code, records production rates, and records machine down time. From a remote location the Production Supervisors can monitor the information to ensure just-in-time delivery to other locations throughout the plant.

Investment and Results
Had we written the four nodes in C/C++, the effort would have been tremendous, and there is no way to accurately estimate the total lines of code it would have taken for development. Also, with C/C++, the length of time would have been too great to meet Toshiba’s targeted date. Using LabVIEW, this process was completed in 16 weeks. The success of the initial four nodes led to other opportunities with Toshiba Display Devices. To date, we have used LabVIEW to control 10 of the 15 production lines in this 1 million sq ft facility.

According to one ORTHSTAR engineer, "We like using LabVIEW because we can develop a customized system to meet each customers unique requirements. Also the flexibility of LabVIEW ensures that we can scale the system to increase its capabilities as the customers needs increase or as changes need to be applied."

For more information, contact:

David Potter

ORTHSTAR Inc.

Airport Corporate Park, PO Box 459

Big Flats, NY 14814-0459

Tel: 607-562-2100 x231

E-mail: potter@orthstar.com

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