PHA, a world leader in the automotive subassembly business, has seven Korean plants, seven plants in the Czech Republic, Slovakia, China, India and the USA and three worldwide sales branches.
The company’s Czech Republic plant, PHA Czech s.r.o., in ?eský T?šín, 300 km east north of Prague, started production in 2008 and employs 300 people and concentrates primarily on the production of door modules for a leading Korean automotive OEM.
It also produces non-module door hinges, bonnet/hood hinges, tailgate hinges and tailgate latches, not only for the Korean car maker, but for a number of other leading automotive OEMs.
In a recent development program, the Rockwell Automation Global Solutions team in the Czech Republic team was tasked by PHA Czech s.r.o. with the development of a complete control solution for a front/rear, left/right turnkey door module assembly line and end-of-line (EOL) test stations.
The scope of delivery given to the Global Solutions team, which has been working with PHA since 2006, involved project management, administration, hardware & software design, cabinet manufacture, site installation, commissioning and production start-up.
The assembly line – the fifth to be developed by Rockwell Automation for PHA; and the first door module line built on a conveyor concept, where the panels move on pallets and the operators stay in one place – had to be designed to meet demanding production capacities and targets.
Capable of building 850 car sets per day it had to be flexible enough to address the possibility of extending this to 1,000 car sets per day.
PHA also wanted enhanced quality levels and various process optimisation steps based on both knowledge from previous installs and newer standards and targets defined by more recent end-user customer requirements.
A comprehensive machine and personnel safety solution was also part of the brief.