Automatic Vehicle Identification System (AVI) Training Manual

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1 Automatic Vehicle Identification System (AVI) Training Manual Chapter 7: Supervisory User Interface Owner: APICS Page 1 of 50 Revision: 1.34

2 TABLE OF CONTENTS 7 SUPERVISORY USER INTERFACE APIC MERCURY OVERVIEW GETTING AROUND NAVIGATION STRIP, SCREENS, TOOLS OPTIONS, HELP Navigation Strip Screens Tools Options Help VEHICLE TOOLS Search Search Vehicles Aged Edit No Build Label Replacement Scrap Clone Applications Broadcast Data Request AREA TOOLS Search View Lanes Search Lanes View Point Data Applications Schedule Request Mixed Bank Overview Screen Configuration Queue Maintenance Screens SYSTEM TOOLS NS Request Paint Shop Counts Paint Shop Inventory...50 Owner: APICS Page 2 of 50 Revision: 1.34

3 Document Revision History Date Revision Number Name Description (include pages affected) 2009 Feb Mas40 Change name to Chrysler 2007 Jan MAS40 Updates from BRAP launch Dec MAS40 Updates from BRAP launch Dec MAS AVI Training Manual Update Project Supporting Documentation The Chrysler documents listed below are instrumental in defining this chapter's systems and its configuration. Doc. No. Rev. Date Title Link None Note: APICS Mercury has its user documented embedded in the help menu of application. Owner: APICS Page 3 of 50 Revision: 1.34

4 7 SUPERVISORY USER INTERFACE The primary application used by personnel in the plant for interfacing with AVI Worckell applications is the APIC Mercury application. It is part of the standard Chrysler Plant PC load. Other software applications / tools exist to interface with the AVI Workcell. These applications are more complex UNIX based programs used by the System Administrators and APIC development staff. 7.1 APIC Mercury Overview APIC Mercury is a suite of utilities to assist in assembly plant production. APIC Mercury allows a user to view vehicle production, vehicle progress, vehicle options, scheduling and when necessary vehicle rescheduling. Figure 7-1 shows an example process with AVI points where a plant user may want to know what vehicles/parts are present in realtime. Figure 7-1: BIW AVI Process Flow Diagram (Not part of APIC Mercury) Owner: APICS Page 4 of 50 Revision: 1.34

7.2 Getting Around Navigation Strip, Screens, Tools Options, Help Within APIC Mercury the user can open as many windows as needed, navigate, arrange and manage the windows by accessing the Window

5 7.2 Getting Around Navigation Strip, Screens, Tools Options, Help Within APIC Mercury the user can open as many windows as needed, navigate, arrange and manage the windows by accessing the Window menu at the top of the screen. APIC Mercury has the ability to save open windows and their positions on the screen. Follow the steps below to save a screen with multiple windows open (Figure 7-2) Click on the Windows menu. 2. Select Save Window State. Figure 7-2: Windows Menu Owner: APICS Page 5 of 50 Revision: 1.34

1 2 3 Figure 7-4: Open a Saved Window Follow the steps below to open a saved window (Figure 7-4): 1.

6 3 Figure 7-3: Save Window State Screen 3. Enter the name of the window to be saved and select Save Window (Figure 7-3) Figure 7-4: Open a Saved Window Follow the steps below to open a saved window (Figure 7-4): 1. Click on the Windows menu. 2. Select Open Window State. 3. Select the name of the window saved. For example, Test. 4. The windows appear as saved. Owner: APICS Page 6 of 50 Revision: 1.34

The user is able to delete or rename a saved window. Follow the steps below to manage the saved window (Figure 7-5): Figure 7-5: Manage Saved Window Screen 1.

7 The user is able to delete or rename a saved window. Follow the steps below to manage the saved window (Figure 7-5): Figure 7-5: Manage Saved Window Screen 1. Click on the Windows menu. 2. Select Manage Saved Window State. 3. Select the name of the window that needs to be deleted or renamed. 4. Select or. 5. Select. Owner: APICS Page 7 of 50 Revision: 1.34

8 7.2.1 Navigation Strip The navigation strip (Figure 7-6) is used to steer the user to the appropriate function within APIC Mercury. The navigation strip contains three tabs: Tool Explorer, Search Vehicles and Browse Areas. Note: Double clicking on the navigation strip will minimize the left side menu. Navigation Strip Figure 7-6: Navigation Strip Owner: APICS Page 8 of 50 Revision: 1.34

9 When is selected from the navigation strip, Figure 7-7 illustrates the list of possible folders to be viewed. Figure 7-7: Tool Explorer Tab Owner: APICS Page 9 of 50 Revision: 1.34

10 When is selected from the navigation strip, Figure 7-8 displays the fields to be used to search for a vehicle. Figure 7-8: Search Vehicles Tab Owner: APICS Page 10 of 50 Revision: 1.34

11 When is selected from the navigation strip, Figure 7-9 displays the areas available to be browsed. Figure 7-9: Browse Areas Tab Owner: APICS Page 11 of 50 Revision: 1.34

12 7.2.2 Screens When is selected from the navigation strip Figure 7-10 illustrates a list of folders that contain numerous screens that assist the user in viewing the assembly plant production. Figure 7-10: Tool Explorer Folders Owner: APICS Page 12 of 50 Revision: 1.34

13 The folder contains applications to assist the user in browsing and searching for vehicles in production. Figure 7-11 illustrates the vehicle tools screen. Figure 7-11: Vehicle Tools Screen Owner: APICS Page 13 of 50 Revision: 1.34

14 The folder contains applications to view and search real time activities. Figure 7-12 illustrates the Area Tools screen. Figure 7-12: Area Tools Screen The folder contains applications to grant user access and to start and stop next in sequence requests. Only an administrator can access the screens within Systems Tools. Figure 7-13 illustrates the System Tools screen. Figure 7-13: System Tools Screen Owner: APICS Page 14 of 50 Revision: 1.34

15 The folder contains APIC applications in the old format. Figure 7-14 illustrates the Legacy Tools screen. Figure 7-14: Legacy Tools Screen Owner: APICS Page 15 of 50 Revision: 1.34

Select Tools Options by clicking on Tools on the menu bar at the top of the screen (Figure 7-15). 2. Select Options. Figure 7-15: Tools Menu 3.

16 7.2.3 Tools Options Tools Options is used to configure the APIC Mercury system within an application. The following steps describe how to select Tools Options. 1. Select Tools Options by clicking on Tools on the menu bar at the top of the screen (Figure 7-15). 2. Select Options. Figure 7-15: Tools Menu 3. Select the application to be configured. For example, select Vehicle Search (Figure 7-16). 4. Select the Search Fields tab, Display Fields tab, or Saved Searches tab to select the fields to be configured. Figure 7-16: Vehicle Search Options Screen Owner: APICS Page 16 of 50 Revision: 1.34

17 7.2.4 Help The help menu is accessed by selecting Help on the menu at the top of the screen or by selecting the F1 function key (Figure 7-17). The help section will be similar in content to this guide and explain screens and processes used in this application. Figure 7-17: Help Screen Owner: APICS Page 17 of 50 Revision: 1.34

18 7.3 Vehicle Tools This section will describe the vehicle tool functions that search for vehicles, edit vehicle production, and update applications for specific vehicles Search APIC Mercury has the ability to search for a specific vehicle and the ability to search for aged vehicles. A specific vehicle search can be done by entering specific criteria of that vehicle or set of vehicles. A search for aged vehicles locates vehicles that have lapse a specific time period Search Vehicles 1. Click from the navigation strip. Figure 7-18: Search Vehicles Screen 2. There are three ways to search for a vehicle (Figure 7-18): Enter the search criteria by inputting the VIN. The Vehicle Data screen will appear as shown in Figure Select a previously saved search. Owner: APICS Page 18 of 50 Revision: 1.34

Search multiple vehicles by selecting the search operation from the drop down arrow and inputting the BC Status, Track Seq. or Gateline Seq (Figure 7-19).

19 Search multiple vehicles by selecting the search operation from the drop down arrow and inputting the BC Status, Track Seq. or Gateline Seq (Figure 7-19). Table 7-1 describes the search operations and search parameters when doing a multiple search. The Search Vehicles screen will then appear as shown in Figure A B C Identifier Purpose Description Figure 7-19: Multiple Vehicle Search A Search operation From the drop down select from the following: = equals < less than > greater than <= less than equal to >= greater than equal to!= not equal <> outside that range (Not equal to) << less than least of the values >> greater than greatest of the values B Search parameter Broadcast Status enables a search for a range, E-G, using a dash between the two ranges. This function is only available in Broadcast Status C Search parameter Tack Sequence and Gateline sequence search parameters are able to do multiple subset searches. Table 7-1: Description of Multiple Vehicle Search 3. Click Find Vehicles. Owner: APICS Page 19 of 50 Revision: 1.34

Figure 7-20: Vehicle Detail Screen The screen is divided into four sections: detail fields (top half of the screen), style options, history and control data.

20 Figure 7-20: Vehicle Detail Screen The screen is divided into four sections: detail fields (top half of the screen), style options, history and control data. To view more of the screen, the screen can be resized. The user can change how much of the screen is dedicated to the detail fields and how much is dedicated to style options, history and control data. To do so, hover the mouse in the boundary areas between the grids. Click and drag to resize the areas when the cursor changes to a horizontal or vertical line with perpendicular arrows. The columns within the style options, history and control data may also be rearranged. From the Vehicle Detail screen the following functions can be completed and are explained in detail throughout the manual: Vehicle Search Label Replacement Refresh From Broadcast No Build Build Scrap Owner: APICS Page 20 of 50 Revision: 1.34

A B C D 2 E Figure 7-21: Search Vehicles Screen for Multiple Vehicles Identifier Field Name Description A Options Click to modify the search and display fields.

21 A B C D 2 E Figure 7-21: Search Vehicles Screen for Multiple Vehicles Identifier Field Name Description A Options Click to modify the search and display fields. B C D Schedule Points A search can be saved. In order to view a specific search again, click on. A dialog opens, enter the search name and click Table 7-2: Search Vehicles Screen Description Note: The order of columns displayed on the Multiple Vehicle Search screen can be changed and retrieved when the screen is opened the next time. Owner: APICS Page 21 of 50 Revision: 1.34 again. Is available when a user needs to save an already existing saved search as a new search. Key ID points throughout the plant. Range from Not incremental. To find out what the schedule points reference go to Browse Areas tab on the navigation strip and select Scheduled Points. E 0, 1, 2. 0 indicates that the vehicle has not passed the scheduled point A non 0 value indicates the vehicle passed the scheduled point and has that numbered option Each option has its own color

7.3.2 Aged The Aged Vehicle Screen displays the vehicle VIN and the vehicle identifiers created at the different points of the manufacturing process. 1. Click. 2. Click 3. Click on.

22 7.3.2 Aged The Aged Vehicle Screen displays the vehicle VIN and the vehicle identifiers created at the different points of the manufacturing process. 1. Click. 2. Click 3. Click on. Figure 7-22: Aged Vehicles 4. Select the report by clicking the radio button in front of the report needed or customize the report by selecting the start point ID, end point ID or hours aged (Figure 7-22). 5. Click. Owner: APICS Page 22 of 50 Revision: 1.34

23 Figure 7-23: Aged Screen Note: Underlined blue VINs throughout APIC Mercury indicate a hyperlink to the Vehicle Detail Screen. Owner: APICS Page 23 of 50 Revision: 1.34

24 7.3.3 Edit APIC Mercury has the ability to edit vehicle information in the functions No Build, Replace Label, Scrap Vehicle, and Clone Creation. The No build status allows a pause in the production of a specific vehicle by removing the vehicle from the production line. Replace label is used when a label has been torn, painted or missing. Scrap vehicle is used when a vehicle needs to be scrapped. Clone Creation is used when a vehicle or part of a vehicle needs a clone for testing or other developmental purposes No Build 1. From the detail screen, click the Edit drop down arrow. 2. Select No Build Status. 3. Drag the mouse to the right to select No Build. Note: When the vehicle is able to continue production, place the vehicle back in build status by selecting Build Figure 7-24: No Build Screen Owner: APICS Page 24 of 50 Revision: 1.34

7.3.3.2 Label Replacement 1. From the Vehicle Detail screen, click the Edit drop down arrow. 2.

25 Label Replacement 1. From the Vehicle Detail screen, click the Edit drop down arrow. 2. Select Replace Label. 1 2 Figure 7-25: Replace Label Selection Owner: APICS Page 25 of 50 Revision: 1.34

3 4 5 Figure 7-26 - Replace Label 3. Select primary barcode or secondary label that will be replaced. 4. Enter new barcode label number. 5. Click to enable the label replacement. 6.

26 3 4 5 Figure Replace Label 3. Select primary barcode or secondary label that will be replaced. 4. Enter new barcode label number. 5. Click to enable the label replacement. 6. Confirm validation of the label replacement. The Replace Label screen closes and the Vehicle Data screen displays the VIN details for the entered VIN. This will show the new association of Label-B with the VIN. Note: If validation fails, the process to replace the label is stopped and the focus is set to the Label-B field for a new entry Scrap 1. From the Vehicle Detail screen, click Scrap. 2. A confirmation screen appears Clone 1. Click. 2. Click 3. Click Owner: APICS Page 26 of 50 Revision: 1.34

27 4 5 Figure 7-27: Step 1 of Clone Creation 4. Select a source template for the clone. 5. Click. Figure 7-28: Build Details Tab The data that is shown is from the template selected. All data is configurable at the server. The Gateline Sequence is calculated based on the sequence from the selected template. Owner: APICS Page 27 of 50 Revision: 1.34

Note: A clone needs the following information to create a vehicle: Build Sequence Number Broadcast Status Label (if post marriage type) Marriage Type Vehicle Type Production Year Style Options VIN

28 Note: A clone needs the following information to create a vehicle: Build Sequence Number Broadcast Status Label (if post marriage type) Marriage Type Vehicle Type Production Year Style Options VIN Control Options Label Control Options (if post marriage type) : Style Options Tab 6. Select the Style Options tab. 7. Select the style options for the clone. Owner: APICS Page 28 of 50 Revision: 1.34

11 10 Figure 7-31: Label Details Tab 10. Select the Label Details tab. 11.

29 8 Figure 7-30: VIN Control Options Tab 8. Select the VIN Control Options tab. 9. Select the appropriate VIN control options for the clone Figure 7-31: Label Details Tab 10. Select the Label Details tab. 11. Enter the barcode label number and label details. 12. Select. 12 Owner: APICS Page 29 of 50 Revision: 1.34

7.3.4 Applications Broadcast Data Request coordinates records from broadcast to APIC. Broadcast holds the master information of a vehicle build.

30 7.3.4 Applications Broadcast Data Request coordinates records from broadcast to APIC. Broadcast holds the master information of a vehicle build. Broadcast Data Requests are done to get the latest specifications from broadcast for a specific vehicle Broadcast Data Request 1. From the Vehicle Detail Screen, click the drop down arrow Figure Select Refresh from Broadcast. 1 2 Figure 7-32: Refresh From Broadcast Owner: APICS Page 30 of 50 Revision: 1.34

7.4 Area Tools This section will describe the area tool functions that search for vehicles and update applications for specific vehicles. 7.4.1 Search APIC Mercury has the ability to search for a specific vehicle in a specific area of the plant using the Search Lanes and View Lane functions.

31 7.4 Area Tools This section will describe the area tool functions that search for vehicles and update applications for specific vehicles Search APIC Mercury has the ability to search for a specific vehicle in a specific area of the plant using the Search Lanes and View Lane functions. The View Lane function shows the vehicles on a given lane which enables a specific vehicle to be followed. APIC Mercury has the ability to verify a vehicle has passed a certain AVI point by using the Point Detail function View Lanes 1. Click from the navigation strip. 2. Click to expand the lanes to be viewed Figure 7-33: Lane Selection 3. Click on a folder to view the lanes. 4. Click on a lane to view the vehicles as they are positioned on the conveyor. Owner: APICS Page 31 of 50 Revision: 1.34

7.4.1.2 Search Lanes 1. Click from the navigation strip. 2. Click. 3. Click. 4 5 Figure 7-34: Search Lanes Screen 4. Select VIN or Label and enter the information for the vehicle.

32 Search Lanes 1. Click from the navigation strip. 2. Click. 3. Click. 4 5 Figure 7-34: Search Lanes Screen 4. Select VIN or Label and enter the information for the vehicle. Note: Perform a wild card search by using an * asterisk. For example, to find all VINs that start with 7C, type 7C*. 5. Click. If vehicles matching the search criteria are found, results will appear at the bottom of the screen. Double click on a search result to open a view window for the queue where that vehicle currently resides. Owner: APICS Page 32 of 50 Revision: 1.34

7.4.1.3 View Point Data 1. Click from the navigation strip. 2. Click to expand the AVI points to be viewed. 4 Figure 7-35: Point Detail Screen 3.

33 View Point Data 1. Click from the navigation strip. 2. Click to expand the AVI points to be viewed. 4 Figure 7-35: Point Detail Screen 3. Select an AVI point from the left side menu. 4. View the list of VINs and the date and time that they have gone though the specific point selected. Owner: APICS Page 33 of 50 Revision: 1.34

7.4.2 Applications Schedule Request allows the user to view the status of each scheduled request point and the status of what is to be built and what has been built for a specific day.

34 7.4.2 Applications Schedule Request allows the user to view the status of each scheduled request point and the status of what is to be built and what has been built for a specific day. Mixed Bank visual tool gives the user real time information to ensure the manufacturing process is optimized to the fullest Schedule Request 1. Click from the navigation strip. 2. Click. 3. Click. B C D A E F G H I J K L M N O P Figure 7-36: Schedule Request Production Counts Screen Identifer A B Description Defined scheduling points in the system Point Request Mode can be auto, manual or bypass/ratio Owner: APICS Page 34 of 50 Revision: 1.34

C D E F G H I J K L M N O P Click Edit to change the number of vehicles to be manufactured Configure: Click to change Options Counts Mode tab: Stats of all vehicles to be built and have been built

35 C D E F G H I J K L M N O P Click Edit to change the number of vehicles to be manufactured Configure: Click to change Options Counts Mode tab: Stats of all vehicles to be built and have been built Type: Vehicle make APIC Inhibit: Programming level info PLC Inhibit: Programming level info NO Inventory: Programming level info Available: Number of vehicles to be built Auto: Automatically configured vehicles Manual: Manually configured vehicles Bypass: Human intervention not allowing some vehicles to be built Build: Number of vehicles to be built Schedule Response Mode Display the count as a percentage Table 7-3: Schedule Request Production Counts Screen Description A C D E F G H B Figure 7-37: Schedule Request Pool of VINs Screen Owner: APICS Page 35 of 50 Revision: 1.34

Identifier A B C D E F G H Description Pool of VINs tab Double click VIN to go to the Vehicle Detail screen Gateline Sequence Tracked Sequence Broadcast Status VIN Control (22): Vehicle options

36 Identifier A B C D E F G H Description Pool of VINs tab Double click VIN to go to the Vehicle Detail screen Gateline Sequence Tracked Sequence Broadcast Status VIN Control (22): Vehicle options programmer level Species: Metal part ID Make/Model (Sty01): Vehicle options administrator level Table 7-4: Schedule Request Pool Screen Description B A C Figure 7-38: Schedule Request Last Transaction Screen Owner: APICS Page 36 of 50 Revision: 1.34

37 Identifier A B C Description Last Transaction tab describes the last vehicle built at the scheduling point selected. Information from the last request Information about the response type from the workcell Table 7-5: Schedule Request Last Transaction Screen Description Owner: APICS Page 37 of 50 Revision: 1.34

38 7.4.3 Mixed Bank Overview Screen - Floor The floor operator screens are a mix of OEM control screens along with standard AVI screens (Point Status and GS/GN screens) Overview Screen - Supervisory Figure 7-39: APICS Mercury Mixed Bank View Screen (BAP example) The APICS Mercury Mixed Bank View screen (Figure 7-39) allows the user to view the selectivity bank from a top of the sky view. Besides being a graphical representation of the real world, the user can also find the vehicle ID of any vehicle by placing the cursor on the desired vehicle and the vehicle ID pops up (contextual help feature). Owner: APICS Page 38 of 50 Revision: 1.34

7.4.3.3 Configuration The configuration screen of Mixed Bank is where the rules of Mixed Bank are established.

39 Configuration The configuration screen of Mixed Bank is where the rules of Mixed Bank are established. Mixed Bank configuration is a password protected screen. Figure : Access to Mixbank Configuration Owner: APICS Page 39 of 50 Revision: 1.34

Figure 7-41: APICS Mercury Mixed Bank Configuration Identifier Description Click to add a new rule (Figure 7-43) Name Description Type Style field Style Byte number Style value Enable Penalty Rule

40 Figure 7-41: APICS Mercury Mixed Bank Configuration Identifier Description Click to add a new rule (Figure 7-43) Name Description Type Style field Style Byte number Style value Enable Penalty Rule Click to edit the selected rule Click to delete the selected rule Click to save the changes made Rule name English explanation of the rule. This is what is displayed on the main screen, Input or output. Usually set as an output rule (main goal is to determine an ordered output). An input rules is used when the output rules cannot be executed. This can be driven from PES or from AVI control bytes 1 PES 2 VIN control bytes 3 Label Control bytes Same as AVI style and control bytes The conversion from Broadcast to AVI style bytes is: Same as PES or control bytes values Rule enable (Broadcast byte 1) / 2 = AVI Style This is set if a penalty is to be used for violations. The amount of penalty applied is based on the cost filed Ratio of cars. Requires two numbers. Ex 1:5 (one in five) Weightage To be used in future. Currently kept at value 1. Cost The value will be used to calculate the amount of penalty for a violation of the rule. Owner: APICS Page 40 of 50 Revision: 1.34

41 Hold Target percentage Report percentage There are various holds that can be set but the base types are: No hold Pilot hold (must be released manually) Batch Hold (vehicles released at a ratio after a certain # is held) Reflects the percentage of vehicle type expected to be delivered to the bank. Expected percentage being shipped from the bank. Table 7-6: APICS Mercury Mixed Bank Configuration Screen Field Descriptions Owner: APICS Page 41 of 50 Revision: 1.34

42 Figure 7-42: Add a Rule Screen Input Figure 7-43: Add a Rule Screen Output Owner: APICS Page 42 of 50 Revision: 1.34

43 Queue Maintenance Screens APICS Mercury Queue Management allows the viewing and manipulation of the vehicles in each lane (along with the vehicle attributes). Figure 7-44: Commands from title bar Figure 7-45: Commands from right click button Owner: APICS Page 43 of 50 Revision: 1.34

44 APICS Mercury Queue maintenance HOLD screens Figure 7-46 Hold Status Change Figure 7-47: Hold Status Change confirmation Owner: APICS Page 44 of 50 Revision: 1.34

45 APICS Mercury Queue maintenance Insert Vehicle screens Figure 7-48: Insert Vehicle Figure 7-49 Insert Vehicle confirmation Owner: APICS Page 45 of 50 Revision: 1.34

46 APICS Mercury Queue maintenance Delete Vehicle screens Figure 7-50 Delete Vehicle Figure 7-51 Delete Vehicle confirmation Owner: APICS Page 46 of 50 Revision: 1.34

47 APICS Mercury Queue maintenance Delete Vehicle screens Figure 7-52 Move Vehicle screen Figure 7-53 Move Vehicle Screen confirmation Owner: APICS Page 47 of 50 Revision: 1.34

48 7.5 System Tools This section will describe the application of an NS Request. The Next in Sequence (NS) Request is the process where the AVI system retrieves new vehicle build information from Broadcast to maintain the pre-marriage count in the database NS Request 1. Click. 2. Click 3. Click. Figure 7-54: Next in Sequence Request Screen Press only in the following situations (Figure 7-54): Material shortage for a block of vehicles scheduled to be built. Modify the orders of broadcast. For example, prevent the next model year vehicles from being downloaded to the WCC. The Active Limit describes the maximum number of vehicles the AVI workcell has downloaded in advance. The Active Count describes the actual number of vehicles AVI has downloaded in advance from broadcast. Owner: APICS Page 48 of 50 Revision: 1.34

49 7.5.2 Paint Shop Counts 1. Click. 2. Click 3. Click. 4. Click. Figure 7-55: Paint Shop Menu Figure 7-56: Paint Shop Counts Owner: APICS Page 49 of 50 Revision: 1.34

50 7.5.3 Paint Shop Inventory 1. Click. 2. Click 3. Click. 4. Click. Figure 7-57: Paint Shop Menu Figure 7-58: Paint Shop Inventory Screen Owner: APICS Page 50 of 50 Revision: 1.34

Automatic Product Identification and Control Systems

Automatic Product Identification and Control Systems Presented by: Larry Vavro, Manager APIC Systems Larry Walker, Senior Manager Assembly Systems Processes 3/12/2002 APIC Systems 1 APIC Systems Topics