Loading
Rockwell Automation Home
  • Industries
    • Industries Chevron RightChevron Right
      • Automotive & Tire
      • Cement
      • Chemical
      • Entertainment
      • Fibers & Textiles
      • Food & Beverage
      • Household & Personal Care
      • Infrastructure
      • Life Sciences
      • Marine
      • Metals
      • Mining
      • Oil & Gas
      • Power Generation
      • Print & Publishing
      • Pulp & Paper
      • Semiconductor
      • Water Wastewater
      • View All
    Industries
    Case StudyRockwell Automation's case studies Case Studies DistributorDistributor How to Buy EventEvent Events
  • Capabilities
    • Capabilities Chevron RightChevron Right
      • The Connected Enterprise®
      • Consulting & Integration Services
      • Cybersecurity
      • Digital Transformation
      • Industrial Analytics
      • Industrial Automation & Control
      • Industrial Maintenance & Support
      • Industrial Networks
      • Lifecycle Services
      • Machine & Equipment Builders
      • MES Solutions
      • Process Solutions
      • Safety Solutions
      • View All
    Capabilities
    Blogs DistributorDistributor How to Buy EventEvent Events
  • Products
    • Hardware Chevron RightChevron Right
    • Software Chevron RightChevron Right
      • Circuit & Load Protection
      • Condition Monitoring
      • Connection Devices
      • Distributed Control Systems
      • Drives & Motors
      • Energy Monitoring
      • Human Machine Interface
      • Independent Cart Technology
      • Industrial Computers & Monitors
      • Input/Output Modules
      • Industrial Control Products
      • Lighting Control
      • Motion Control
      • Motor Control
      • Networks Security & Infrastructure
      • Packaged Solutions
      • Power Supplies
      • Programmable Controllers
      • Push Buttons & Signaling Devices
      • Relays & Timers
      • Safety Instrumented Systems
      • Safety Products
      • Sensors & Switches
      • Signal Interface
      • View All Hardware Products
    • DesignSuite
      • Dynamic Digital Twin Software
      • Studio 5000 Design Software
    • OperationSuite
      • FactoryTalk Edge Gateway
      • FactoryTalk Batch
      • FactoryTalk Historian
      • FactoryTalk View - HMI Software
      • FactoryTalk Metrics
    • MaintenanceSuite
      • FactoryTalk Analytics for Devices
      • FactoryTalk AssetCentre
      • FactoryTalk Emonitor
      • FactoryTalk Network Manager
      • FactoryTalk TeamONE
      • Fiix CMMS
    • InnovationSuite
      • Augmented Reality
      • FactoryTalk Analytics
      • MES
      • ThingWorx IIoT Platform
    Products
    Find Products by Our Brands: Allen-Bradley FactoryTalk
  • Support
    • Product Support Chevron RightChevron Right
    • Documentation Chevron RightChevron Right
    • Knowledgebase Chevron RightChevron Right
    • Training Chevron RightChevron Right
    • Downloads
      • 2D & 3D Drawings
      • Activations
      • Add-on Profiles
      • Application Code Libraries
      • Compatibility & Downloads
      • Drivers & Firmware
      • Electronic Datasheets
      • EPLAN Macros
      • Sample Code Library
      • Software Patches
      • View All
    • Selection & Configuration
      • Control Systems Configuration Tools
      • Procurement Specifications
      • ProposalWorks Proposal Builder
      • Global Short-circuit Current Ratings Tool
      • Integrated Architecture Builder
      • View All
    • Compatibility & Migration
      • Migration & Modernization
      • Lifecycle Status
      • Product Replacement Lookup
      • View All
      • Technical Documentation Center
      • Technical Specifications
      • Product Certifications
      • Product Drawings
      • Release Notes
      • Literature Library
    • Support Center
      • Support Options
      • Search for Answers
      • Chat Online
      • Call Us
      • View All
    • Online Forum
      • My Inbox
      • My Favorites
      • My Subscriptions
      • View All
    • My TechConnect
      • Chat History
      • Service Ticket History
      • Manage Your Favorite Answers
      • Field Service Request
      • View All
      • E-Learning Courses
      • Training Workstations
      • Training Calendar
      • View All
    Support
    Contact Us HelpHelp Get Support LaunchpadTools and applications View All Tools
  • Company
    • Events Chevron RightChevron Right
    • News Chevron RightChevron Right
    • Careers Chevron RightChevron Right
    • PartnerNetwork Chevron RightChevron Right
    • About Us Chevron RightChevron Right
    • Featured Events
      • Automation Fair
      • Process Solutions User Group
      • Smart Machine Workshops
      • VirtualConnect: Smart Manufacturing
      • View All
    • Webinars
      • Live
      • On-Demand
      • View All
      • Blogs
      • Case Studies
      • Automation Today
      • Podcasts
      • Press Releases
      • Media Contacts
      • View All
      • View Jobs
      • Teams & People
      • Hackathon
      • Employee Video Spotlight
      • Authorized Distributors
      • Encompass Product Partners
      • Licensed Developers
      • OEM Partners
      • Strategic Alliance Partners
      • System Integrator Partners
      • PartnerNetwork Portal
      • View All
      • Our Brands
      • Our Community
      • Our History
      • Integrity & Sustainability
      • Investor Relations
      • View All
    Company
    ProductivityProductivity Investor Relations
  • Sales
  • Sales
  • View All Industries
  • View All
  • View All
  • View All
  • View All
  • Automotive & Tire
  • Cement
  • Chemical
  • Entertainment
  • Fibers & Textiles
  • Food & Beverage
  • Household & Personal Care
  • Infrastructure
  • Life Sciences
  • Marine
  • Metals
  • Mining
  • Oil & Gas
  • Power Generation
  • Print & Publishing
  • Pulp & Paper
  • Semiconductor
  • Water Wastewater
  • View All
  • The Connected Enterprise®
  • Consulting & Integration Services
  • Cybersecurity
  • Digital Transformation
  • Industrial Analytics
  • Industrial Automation & Control
  • Industrial Maintenance & Support
  • Industrial Networks
  • Lifecycle Services
  • Machine & Equipment Builders
  • MES Solutions
  • Process Solutions
  • Safety Solutions
  • View All
  • Circuit & Load Protection
  • Condition Monitoring
  • Connection Devices
  • Distributed Control Systems
  • Drives & Motors
  • Energy Monitoring
  • Human Machine Interface
  • Industrial Computers & Monitors
  • Input/Output Modules
  • Industrial Control Products
  • Lighting Control
  • Motion Control
  • Motor Control
  • Networks Security & Infrastructure
  • Packaged Solutions
  • Power Supplies
  • Programmable Controllers
  • Push Buttons & Signaling Devices
  • Relays & Timers
  • Safety Instrumented Systems
  • Safety Products
  • Sensors & Switches
  • Signal Interface
  • View All Hardware Products
  • View All
  • View All
  • Technical Documentation Center
  • Technical Specifications
  • Product Certifications
  • Product Drawings
  • Release Notes
  • Literature Library
  • View All
  • Training Workstations
  • Training Calendar
  • View All
  • View All
  • Blogs
  • Automation Today
  • Podcasts
  • Media Contacts
  • View All
  • View Jobs
  • View All
  • Authorized Distributors
  • Encompass Product Partners
  • Licensed Developers
  • OEM Partners
  • System Integrator Partners
  • PartnerNetwork Portal
  • View All
  • Our Brands
  • Our History
  • Investor Relations
  • View All
  • iTRAK Intelligent Track Systems
  • MagneMover Lite Intelligent Conveyor System
  • QuickStick Intelligent Conveyor System
  • View All
  • Dynamic Digital Twin Software
  • Studio 5000 Design Software
  • FactoryTalk Edge Gateway
  • FactoryTalk Batch
  • FactoryTalk Historian
  • FactoryTalk View - HMI Software
  • FactoryTalk Metrics
  • FactoryTalk Analytics for Devices
  • FactoryTalk AssetCentre
  • FactoryTalk Emonitor
  • FactoryTalk Network Manager
  • FactoryTalk TeamONE
  • Fiix CMMS
  • Augmented Reality
  • FactoryTalk Analytics
  • MES
  • ThingWorx IIoT Platform
  • 2D & 3D Drawings
  • Activations
  • Add-on Profiles
  • Application Code Libraries
  • Compatibility & Downloads
  • Drivers & Firmware
  • Electronic Datasheets
  • EPLAN Macros
  • Sample Code Library
  • Software Patches
  • View All
  • Control Systems Configuration Tools
  • Procurement Specifications
  • ProposalWorks Proposal Builder
  • Global Short-circuit Current Ratings Tool
  • Integrated Architecture Builder
  • View All
  • Migration & Modernization
  • Lifecycle Status
  • Product Replacement Lookup
  • View All
  • Support Options
  • Search for Answers
  • Chat Online
  • Call Us
  • View All
  • My Inbox
  • My Favorites
  • My Subscriptions
  • View All
  • Chat History
  • Service Ticket History
  • Manage Your Favorite Answers
  • Field Service Request
  • View All
  • My Training
  • View All
  • Automation Fair
  • Process Solutions User Group
  • Smart Machine Workshops
  • VirtualConnect: Smart Manufacturing
  • View All
  • Live
  • On-Demand
  • View All
  • Digital Transformation at Norbord
  • View All
  • Brighter, More Flexible Tower Light Now Available from Rockwell Automation
  • Delphi Award Received For Asset Management
  • Internal Bypass Expands Smart Motor Functionality
  • New IaaS Bundle Eases Industrial Networking
  • Rockwell Automation Names Sebastien Grau as Regional Sales Director for Middle East, Turkey and Sub Saharan Africa
  • Expanded Power Range for PowerFlex 6000 MV Drives
  • Studio 5000 Software Update Optimizes Productivity
  • FLEX 5000 I/O Modules Bring Greater Productivity and Flexibility to a Connected Enterprise
  • New Cable-Pull Switch Enhances Industrial Safety
  • Instant Industrial Device Analytics
  • Rockwell Automation to name Al Ghandi Electrical & Automation as Authorised Distributor in the UAE
  • Rockwell Automation to Broaden Connected Enterprise Consulting Expertise with Acquisition of Kalypso
  • Single-Control Multi-Well Pad Solution Cuts Costs
  • Advanced Light Curtain System Improves Flexibility and Safety
  • Automation University
  • Rockwell Automation to Showcase the ConnectedProduction Solutions and Premieres its ThinManager Software at ADIPEC 2018
  • Safe Torque Off Option Simplifies Machine Design
  • Machine Performance Analytics Bring OEM Expertise Into Producer’s Digital Environment
  • Software-Powered Connected Services
  • New Managing Director of Rockwell Automation for Sub-Saharan Africa announced
  • Rockwell Automation Simplifies Analytics for Industrial Productivity
  • New Managing Director of Rockwell Automation for Sub-Saharan Africa announced
  • Securely Deploy Cloud and Mobile Technologies with New Network Guidance
  • Rockwell Automation drive system selected for Sumitomo Rubber’s rubber mixers
  • PlantPAx DCS Roadmap
  • View All
  • Students & New Grads
  • View All
  • Hackathon Use Case for Manufacturing Optimization
  • Hackathon Use Case for Sustainability
  • Hackathon Use Case for Visual System Modernization
  • Hackathon Use Case for Dynamic Filtering
  • View All
  • 24toCode Event Recap - Winter 2019
  • 24toCode Event Recap // IT Internal Hackathon
  • Meet the 2019 IT Summer Interns
  • 24toCode Promo Video
  • Harbor View Plaza Ribbon Cutting
  • Check Your Blind Spots Mobile Tour at Rockwell Automation
  • Mechanic & Tool Apprenticeship at Rockwell Automation
  • Working at Rockwell Automation in Karlsruhe
  • Summer Internships at Rockwell Automation
  • The Intrapreneurial Skills Accelerator at Rockwell Automation
  • Makers Wanted
  • #LifeatROK w Katowicach
  • IT Summer Internship Program
  • #LifeatROK with Diogo
  • View All
  • Cisco
  • Endress+Hauser
  • FANUC
  • Microsoft
  • Panduit
  • View All
  • Our Focused Giving
  • STEM Education
  • Lifelong Learning
  • View All
  • Sustainability Report
  • Our Commitment to Diversity, Equity and Inclusion
  • Environmental, Health, & Safety
  • Ethics & Compliance
  • Global Supply Chain & Sourcing
  • Product Environmental Compliance
  • Quality Management Systems
  • Trust & Security
  • Workforce of Tomorrow
  • View All
Case StudyRockwell Automation's case studies Case Studies DistributorDistributor How to Buy EventEvent Events
Blogs DistributorDistributor How to Buy EventEvent Events
Find Products by Our Brands:
Allen-Bradley FactoryTalk
Contact Us HelpHelp Get Support LaunchpadTools and applications View All Tools
ProductivityProductivity Investor Relations
  • Literature LibraryLiterature Library
    Literature Library

    Access technical and commercial publications for hardware and software products, applications, services and solutions.

    PCDCProduct Compatibility and Download Center
    Compatibility & Downloads

    Find downloads including firmware, release notes, associated software, drivers, tools and utilities.

    KnowledgebaseKnowledgebase Support Center
    Knowledgebase

    Browse the database of questions and answers on a variety of products and technologies.

    Product ConfiguratorProduct Configurator
    Product Configurator

    Configure and select products rapidly.

    Software SubscriptionsSoftware Subscriptions
    Software Subscriptions

    One stop shopping for software and subscription services.

    2D & 3D Drawings Bill of Materials CrossWorks Electronic Datasheets Motion Analyzer My Equipment My Training E-Learning Portal Product Lifecycle Status Product Registration Product Selection Toolbox Repairs Sample Code Library Software Activations View All
    Tools
    UserUser Sign In/Create an Account
  • User Account User
Tools
Literature LibraryLiterature Library
Literature Library
PCDCProduct Compatibility and Download Center
Compatibility & Downloads
KnowledgebaseKnowledgebase Support Center
Knowledgebase
Product ConfiguratorProduct Configurator
Product Configurator
Software SubscriptionsSoftware Subscriptions
Software Subscriptions
2D & 3D Drawings Bill of Materials CrossWorks Electronic Datasheets Motion Analyzer My Equipment My Training E-Learning Portal Product Lifecycle Status Product Registration Product Selection Toolbox Repairs Sample Code Library Software Activations View All
Case Study
Recent ActivityRecent Activity

PHA Czech Deploys New Door Module Assembly Line and EOL Test Stations

Share This:

LinkedInLinkedIn
TwitterTwitter
FacebookFacebook
PrintPrint
EmailEmail
Main Image

Challenge

  • The Rockwell Automation Global Solutions team in the Czech Republic was challenged with project managing, designing, installing and commissioning a complete turnkey door module assembly line

Solutions

  • Global Solutions team
  • Allen-Bradley ControlLogix PACs
  • Allen-Bradley CompactLogix PACs
  • Allen-Bradley POINT I/O
  • Allen-Bradley PowerFlex drives

Results

  • Demanding production level met with the scope to increase it further
  • Complete project management from initial design to final commissioning performed by Global Solution team in the Czech Republic
  • Customized application windows developed by Rockwell Automation programmers
  • Multiple successful audits by automotive OEM end customer
  • Excellent platform upon which future projects will be based

Background

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 Český Těšín, 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.

Challenge

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.

Solution

For the complete door module car set assembly, there are two lines (front and rear) with conveyors carrying the front door module down one side and the rear down the other.

These modules are then assembled in parallel using an identical sequence. Assembly operations include: pulley pre-assembly and riveting; drum winding; window regulator assembly; motor and speaker assembly; latch placement and the incorporation of a side-impact sensor and wire harness.

The EOL inspection stations then undertake full door module functionality tests and motor noise sound inspection (in a sound room), deploying a Poka Yoke quality system.

According to Rockwell Automation Account Manager Miroslav Novotny: “This was a complex project, which was made easier thanks to the use of a number of Allen-Bradley® products from our Integrated Architecture portfolio.

The main line controllers on the front and rear lines are Allen-Bradley ControlLogix 1756 L73 programmable automation controller (PAC). The chain conveyors and motors, which handle all aspects of pallet movement are controlled using Allen-Bradley PowerFlex® 525 variable-speed drives.

This comprises lateral and up and down movement of the pallets between workstations, and control of the recirculating conveyor, which takes empty palettes back to the beginning of the production line.”

The ControlLogix PAC collects, collates and controls all the signals from the various assembly stations using an EtherNet/IP network, Stratix™ managed switches and Allen-Bradley POINT I/O™ modules, which have been used due to the long distances involved – the primary conveyor is 15 m long.

At the end of the line, in the testing stations, four Allen-Bradley CompactLogix™ PACs are used, two in the sound rooms and two in final inspection. The ControlLogix PAC also oversees a robot used on part of the line.

The automation solution is completed by a wide variety of Allen-Bradley low-voltage products, including buttons, sensors and other accessories, inside the cabinets deployed at each station.

Finally, the line’s safety infrastructure, which complies with all local safety legislation, comprises a number of Allen-Bradley safety gates, linked together with emergency stops at each station, all connected in series to safety relays within main control cabinet.

Rockwell Automation Global solutions team leader in the Czech Republic, Petr Veselý, explains: “I have worked with PHA for 10 years now and for this project we started with face-to-face meetings with their engineers, who gave us a very detailed specification, including 3D models of the final product.

They also gave us their expectations regarding timings and volume targets. In this instance we supplied the complete solution, not just the control solution and software; we effectively owned and supervised the whole line, including all mechanical and electrical elements.

We also dealt with three local mechanical assembly suppliers and once the concept had been created we then handled all of the approvals within PHA.

“Once the mechanical design had been approved,” Veselý continues, “the manufacturing go ahead was given and the electrical concept was evolved. Once this had been approved, we employed four programmers from the Rockwell Automation office in Prague to create the software.

Two programmers worked on the main line and two on the inspection stations. RSLogix 5000 was used for visualisation and, in answer to one of PHA’s primary demands for flexibility, we applied customised application windows.

Each station uses a separate all-in-one PC touch panel (18 on the main line and 11 in the standalone and test stations) running C# applications programmed by the Rockwell Automation programmers. Further visualisation and control of the main conveyor is supplied by two Allen-Bradley PanelView™ HMIs.

Results

According to Novotny: “This successful project delivery demonstrates the professionalism and capabilities of our Global Solutions, not only in the provision of technical solutions but also in the delivery of complete project management.

The experience and skills obtained in this instance will be adopted as a basis for further similar opportunities in the automotive market, including future projects with PHA. Indeed, we are already in discussions with PHA for the provision of another door assembly for a different car model.”

Przemysław Sakowicz, Manufacturing Engineer at PHA Czech s.r.o. cites fast support, good relations and previous good experiences of working with Rockwell Automation as the primary reasons for using the leading automation provider again: “I know exactly what quality I can expect and Rockwell Automation has very good team of programmers which offers very fast reactions to any issues or challenges we face.

We had multiple customer audits before and during project start up and the auditors were very satisfied with what we have developed with Rockwell Automation, which is very important for us. I would particularly like to thank Petr Veselý and his team for the project fulfilment and management, they met all the requirements from my side.

“With regards to specific benefits of the Rockwell Automation solution,” Sakowicz concludes, “as well as hitting the production targets, we expect to see significantly reduced programming for the new line we are developing as well as the easy tuning and manipulation of the software we have seen in this solution.

The Integrated Architecture has also delivered a more flexible and open platform for both remote troubleshooting and local maintenance.”

Allen-Bradley, ControlLogix, CompactLogix, LISTEN. THINK. SOLVE., POINT I/O, PowerFlex, PanelView Plus, Rockwell Automation and Stratix are trademarks of Rockwell Automation, Inc.
EtherNet/IP is a trademark of the ODVA
Trademarks not belonging to Rockwell Automation are property of their respective companies.

Published 05 December 2016

Subscribe

Subscribe to Rockwell Automation and receive the latest news, thought leadership and information directly to your inbox.

Subscribe

Recommended For You

Loading
  • Technical Question
  • Chat Technical Support
  • Phone Support
  • Contact Sales
  • General Questions
  1. Chevron LeftChevron Left Home Chevron RightChevron Right
  2. Chevron LeftChevron Left Company Chevron RightChevron Right
  3. Chevron LeftChevron Left News Chevron RightChevron Right
  4. Chevron LeftChevron Left Case Studies Chevron RightChevron Right
Discover
  • The Connected Enterprise®
  • Create Your Account
  • Case Studies
  • Events
Information for...
  • Distributors
  • OEM
  • System Integrators
  • Encompass Partners
  • Investors
  • Career Seekers
Contact Us
  • General Questions
  • Technical Questions
  • Local Sales & Service
  • Pricing & Availability
  • Report Ethical Concerns
  • Customer Experience Survey
Site Information
  • Legal
  • Privacy Policy
  • Cookie Preferences
  • Terms of Use
  • Trademarks
Change Country Site SelectionChange RockwellAutomation.com site selection to a different country, region or language Change Country
South Africa/English

Keep Updated With Us

Sign up to receive our latest headlines for free.

Stay Informed Now
Follow Us
BlogRockwell Automation's Blog
Copyright ©2021 Rockwell Automation, Inc.
Home