La Automatización en México, nos vuelve mas competitivos

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Luis Sánchez Venegas
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1 La Automatización en México, nos vuelve mas competitivos

2 Agenda Tendencias en la Manufactura USA Mexico Vs China GLO (Green Light On) VPSS Tipos de Automatización ROI (Retorno de la inversión)

3 TENDENCIAS EN LA MANUFACTURA 3

4 De vuelta a NorteAmerica 4

5 Proyección de sueldos Se pronostica que para el 2015, el nivel de sueldos En China, sea superior que el de Mexico en un 23% 5

The average cost differentials by year to ship a 40 ft container to the U.S. East Coast from Mexico and China are represented in figure 2 below.

6 Costo del Transporte Mexico vs China Manufacturing Shipping and Logistics Costs. Advantage: Mexico The difference in comparative shipping cost between Mexico and China has become exacerbated in recent years due to the rise in oil prices. The average cost differentials by year to ship a 40 ft container to the U.S. East Coast from Mexico and China are represented in figure 2 below. Due to distance, customs, and importation the difference in time in transit from Mexico to the U.S. and China to the U.S. can be as many as 3 weeks. The North American Free Trade Agreement (NAFTA) allows goods produced in Mexico to flow northbound across the U.S. border quickly and efficiently. Mexico vs china manufacturing logistics costs The Reshoring (and Logistics) Debate: Mexico Vs China Manufacturing, Who Has the Upper Hand Now? VS 6

7 Green Light ON GLO

8 Definicion de GLO GLO (Green Light On) = Es un termino que hace referencia al tiempo en el que la maquina esta trabajando; Punzonando, cortando, doblando, etc GLO = Horas trabajadas / 24 x 100

9 Definicion de GLO No se incluye en las horas trabajadas: Carga y descarga Preparacion de la maquina (Set up) Tiempo de inspeccion de piezas Ausencia del trabajador Descansos Turnos no trabajados Espera por material Acomodo de partes Separacion de partes

Promedio Mundial de GLO Punch GLO Laser Glo 90 95

10 Promedio Mundial de GLO Punch GLO Laser Glo Stand Alone Step 1 Aut. Fully Automated

11 Virtual Prototype Simulation System VPSS

12 Que es el VPSS? Es un estudio que se realiza por un equipo de Ingenieros de Amada, el cual incluye todo el proceso de fabricación, desde el cuarto de Ingenieria pasando por el Almacén de materia prima, corte y formado. En este estudio se calcula el GLO de los equipos y se realiza una simulación para incrementar el GLO con una solución propuesta por Amada.

13 VPSS - Recoleccion de datos Data Collection Sampling Categories

14 VPSS Recoleccion de Datos 8 TURRETS SAMPLED W9 W4 W5 W10 W11 W2 W8 W12 15

15 VPSS Analisis de datos AVG. W12 W11 W10 W9 W8 W5 W4 W2 GLO vs. Downtime (NCT) Sampling Results by Machine 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% 49% 41% 38% 30% 26% 31% 24% 16% 16% Check job instruction Stage material Tool change Trial run Data setup Move clamps Work setup/unload Joint separation Product sorting Filing Check quality/quantity Production control Cleanup Zero return Maintenance Waiting Machine Trouble Absence GLO

16 Analisis de datos GLO vs. DOWNTIME (NCT) GE - Average of Machines AVG. 30% 70% 0% 20% 40% 60% 80% 100% Data Setup 0% MAIN DOWNTIME CONTRIBUTORS Absence 10.3% Data Setup 9.4% Joint Separation 8.6% Check Job Instruction 6.4% Waiting 5.9%

22 MINUTES GLO SETUP RED SHEAR Note: comparison does NOT include GE shear

17 VPSS Justificacion de la inversion Throughput Comparison (NCT) Customer vs. AMADA Solution 0:00 1:12 2:24 3:36 4:48 6:00 GE 5:26 AMADA Solution 1:04 4 HOURS 22 MINUTES GLO SETUP RED SHEAR Note: comparison does NOT include GE shear operations. 80% PROCESS REDUCTION! VIPROS 3610LS w/ AS6510 Material Storage Tower & Automated Loader

18 VPSS Justificacion de la Inversion VIPROS 3610LS w/ AS6510 AUTOMATION CAN YIELD EQUIVALENT PRODUCTION OF (4) EXISTIN Turrets 19

VPSS Otro Ejemplo Biblomodel Overall Avg 26% 36% TRUMATIC 26% 11% TAILIFT 7% 52% STRIPPIT 15% 63% TRUPUNCH 18 Tooling Setup, 56% 19% 0% 20% 40% 60% 80% 100% TRUPUNCH 18 STRIPPIT TAILIFT TRUMATIC

19 VPSS Otro Ejemplo Biblomodel Overall Avg 26% 36% TRUMATIC 26% 11% TAILIFT 7% 52% STRIPPIT 15% 63% TRUPUNCH 18 Tooling Setup, 56% 19% 0% 20% 40% 60% 80% 100% TRUPUNCH 18 STRIPPIT TAILIFT TRUMATIC Biblomodel Overall Avg Check Job Instruction 11% 0% 0% 4% 4% Material Setup 4% 0% 7% 0% 3% Tooling Setup 56% 15% 7% 26% 26% Data Setup 0% 0% 0% 11% 3% Move Clamps 0% 0% 0% 4% 1% Work Setup/Unload 11% 15% 22% 0% 12% Joint Separation 0% 0% 0% 4% 1% Scrapping 0% 7% 0% 0% 2% Maintenance 0% 0% 0% 41% 10% Absence 0% 0% 11% 0% 3% Green Light ON 19% 63% 52% 11% 36% 20

Air Blow tooling Reduce punch penetration resulting in faster speeds and

20 Blanking: EMK 3610+ASR Solution Minimize Tool change 58 Station Turret Planning through pre-scheduling Network and Scheduling Power vacuum dies / Air Blow tooling Reduce punch penetration resulting in faster speeds and reduced wear Brush table Minimize environment noise and scratches on material 21

21 TIPOS DE AUTOMATIZACION 25

22 ASR-M General Information Automatic Storage w/ Load & Unload Functionality ASR-M EM + EML Compact Footprint AMNC-F Scheduling Control Flexible Pallet Configuration PICTURED: EMK3610NT + ASR6510M 6 x 4,400 Lbs. Shelf Capacity PALLET CONFIGURATION(S) 4 Shelves (option) 6 Shelves (standard) 8 Shelves (option) 6 Pallets - Standard Optional 4 or 8 Pallets (Special Order) Height: 12 Height: 14 6 Height:

AMS3015 & AMS4020 Modular Automation Solutions AMS Custom Layouts from Standard Blocks Lasers: FO/FOM2/F1/FOL AJ (Fiber) Expandable up to 4 Lasers Customizable Layouts

23 AMS3015 & AMS4020 Modular Automation Solutions AMS Custom Layouts from Standard Blocks Lasers: FO/FOM2/F1/FOL AJ (Fiber) Expandable up to 4 Lasers Customizable Layouts to fit in almost any shop 10 & 15 Shelf Towers + MARS/CSII Automated Storage System Ready AMNC-IT Scheduling Control 5 x 10 (3015) and 6 x 12 (4020) Systems Available 27

24 AS LUL 300 General Information Automatic Storage w/ Load & Unload Functionality AS LUL 300 FOM2, F1, & FOLAJ Compact Footprint AMNC-F Scheduling Control Flexible Pallet Configuration 6,600 Lbs. Shelf Capacity PALLET CONFIGURATION(S) 2 Cutting Pallets - Standard Choose 2 or 3 Raw Material Pallets Choose 4 or 3 Finished Goods Pallets Selection(s) Above = 8 Total Pallets PICTURED: FOM2 3015NT + AS LUL 300 w/ 2 Cutting, 2 Raw & 4 Finished Goods Pallets NOTE(S): 2,000 Lbs. Sheet Capacity Optional Output Station (F1 or FOLAJ ) 1. ASLUL towers are machine specific. 2. LST not required w/ ASLUL. 3. Can retrofit tower to existing laser, but existing LST no longer needed nd tower can be retrofit, but easier & more cost effective to specify twin tower at time of purchase. 5. Pallet designation(s) can be modified by customer. 28

CSII: General Information Compact Storage System for Flexible Manufacturing CS II Compact, Modular Design Customizable to Exact Requirements Easily Expandable NOTE(S): 1.

25 CSII: General Information Compact Storage System for Flexible Manufacturing CS II Compact, Modular Design Customizable to Exact Requirements Easily Expandable NOTE(S): 1. CSII is a customizable system that should be discussed with your product specialist as to make sure both immediate and future requirements are taken into consideration. 2. Number of pallets/bay reduced when utilizing double stack (ie. finished goods/scrap) pallets and/or any system component that runs through a bay. 3. Can be specified as standalone material storage & retrieval system. 4. In some instances non-amada equipment can be tied into CS. * Check machine model & spec. PICTURED: EMLZ3610NT + PDC II + L300 III S + PR III UL 300 L S Connect Punch, Laser, Combi & Bend Input/Output Station Required AMNC-IT Required ISC (FMS Control) Required 6,600 Lbs. Pallet Capacity 16 or 24 Pallets/Bay Standard Single or Twin Tower Configurations * Retrofitable 29

MP-Flexit: General Information Automatic Load & Unload Functionality MP-Flexit 3015 FOM2, F1 & FOLAJ Compact Footprint Fast Cycle Time PICTURED: FOL3015AJNT + MP-Flexit 6,600 Lbs.

26 MP-Flexit: General Information Automatic Load & Unload Functionality MP-Flexit 3015 FOM2, F1 & FOLAJ Compact Footprint Fast Cycle Time PICTURED: FOL3015AJNT + MP-Flexit 6,600 Lbs. Shelf Capacity 2,000 Lbs. Sheet Capacity PALLET CONFIGURATION 2 Cutting Pallets - Standard Single Raw Material Pallet Single Finished Goods Pallet Optional 2 nd Output Station NOTE(S): 1. Loaders are machine specific. 2. LST not required w/ MP-Flexit. 3. Can retrofit tower to existing laser, but existing LST no longer needed. 4. Only available for right-hand-output, 4kW F1. For Use w/ Wood Pallets Smooth Unload AMNC-F Scheduling Control Possible to Interface w/ CSII (Compact Storage System) 30

27 Retorno de la inversion ROI 31

28 ROI La automatización es un aspecto muy importante en el crecimiento de las empresas ya que se ven en la necesidad de: - Incrementar la demanda del producto - Ofrecer productos de mejor calidad - Optimizar el consumo de energía. 32

29 ROI La principal razón de automatizar es el incremento de la productividad, ello se logra racionalizando las materias primas e insumos, reduciendo los costos operativos, reduciendo el consumo energético, incrementando la seguridad de los procesos, optimizando el recurso humano de la empresa y mejorando el diagnostico, supervisión y control de calidad de la producción. 33

30 Ahorros que produce la Automatización Seguridad Calidad Mercadeo y Productos Logística Desechos Ambiente Laboral Energía 34

31 Conclusiones Los proyectos de automatización tendrán éxito si y solo si coinciden con las metas y estrategias de la organización. El proyecto debe de ser entregado a todos los participantes del proyecto, los que deben de estar de acuerdo con sus objetivos y además comprometidos con ellos. La correcta justificación de un proyecto debe dares cuando se conocen todos los ingresos y egresos propios del proyecto. 35

32 Preguntas??? Gracias!!! 36

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