))) Opel Enhances Smart Production Safety

))) RÜSSELSHEIM, GERMANY (March 27, 2002)

"New ways of thinking" and customized automobiles - these are two essential concerns the Adam Opel AG (Rüsselsheim) will utilize as part of its reorientation in communications. Of course, this concept is backed by new, attractive products, such as the Opel Speedster, but also the innovative manufacturing methods used in the various production facilities, such as the new Rüsselsheim factory opened in early 2002, which has the reputation of being today's most modern factory of the world. By the year 2006, Opel will have invested about ten billion Euros in order to continue offering its customers automobile quality in all respects: in terms of variety of models and accessories, of design, workmanship and functioning, of modernity, longevity and maintenance of value. Today's automobile customers demand a state-of-the-art product in terms of technology and aesthetics - at ever competitive prices.

The Adam Opel AG s one of the biggest automobile manufacturers in Europe, and is the market leader in some countries. With about 37,000 people, the company achieved a sales volume of more than 16 billion Euro in 2001. About 1.15 million cars were produced by Opel in 2001 in its numerous European locations, of which roughly two-thirds were exported.

Manufacturing processes of central importance

As a result of high competitive pressure, manufacturing generally plays a central role in the automobile industry. Even slightest modifications in the "adjusting screws" for the overall manufacturing structure may influence the production process, the product quality, or the pricing. So an efficient production and high process reliability are of general importance to the automobile producers. Transparency of processes and their documentation are required to enable manufacturers to keep on analysing where improvements, higher speed or savings can be achieved in production processes and procedures. This way, the companies save time and material, and consumers naturally benefit, too, for example, from punctual deliveries, quality and a fair price.

Safety concept and quality control in one

The new features of the production process at Opel include a safety system that has so far passed the practical test in a pilot phase in the German factory in Eisenach and the Corsa production facility in Zaragoza (Spain). There, it controlled access to 1,200 weld timers, 100 stud welding units and 80 welding computers, logged production data and documented program changes. Thus, sensitive process and system data have been and will remain protected against unauthorised access already in carcass construction. Now, this system will be extended to the production and assembly facilities for all models all over Europe, where it will be used for the first time in 2004.

The safety chain now also includes test beds, ultrasonic testing equipment, programming units, PCs, and inspection devices, e.g., for brakes and air bags. Even the engines are now programmed and quality-tested with the help of a PC. It is quite obvious that the testing parameters of these systems that are crucial for the driver's safety may by no means be changed. After all, human lives may depend on their safe functioning.

The central element of Opel's safety system is a component made by Texas Instruments (TI), a so-called transponder (microchip with an antenna), that is half the size of an ink cartridge. It has a worldwide unique identification and works without physical contact. The system was designed by the International Technical Development Center (ITEZ) of the Adam Opel AG at its Rüsselsheim headquarters and was developed and integrated into manufacturing by Sphinx Electronics (Kenzingen) and Brückmann (Lahnau).

The transponders work on the basis of radio frequency identification (RFID). This technology is based on energy and data transmission using electromagnetic fields. The entire system consists of a transponder (i.e. a microchip with antenna) as well as a reader with an antenna. When a transponder enters the detection range of the reader, the transponder returns its frequency-modulated unique code.

Easy integration and programming

Every employee entitled to modify production parameters in carcass construction, manufacturing and final assembly, is equipped with a glass transponder on his bunch of keys. Access to the control panel of the production machine is only granted, and new data can only be entered, if the transponder code has been verified by the reader. Access is denied if the code is not authorised. This way the possibility of operating errors that are simply due to a lack of knowledge or accidental inputs are automatically ruled out. The employee completes the process by reading the transponder again. A history log offers the opportunity of finding out afterwards, in the event of problems, who made which changes to the manufacturing parameters.

650 programs alone for the stud welding machines

A complex model range with numerous accessory options, colours, different engines and regular special editions are a great organisational challenge to the technicians in terms of job scheduling and production. All plants, systems and computers have to be prepared, set up and configured appropriately before the actual production process starts. The complex set of tasks is demonstrated by an example. For the stud welding machines alone, 650 programs are available that initiate different production steps. If one includes the adhesive bonding and robot systems, one gets a rough idea of the complexity of the task and the immense efforts needed to solve it.

Transponders suitable for carcass construction

The RFID transponders have proven their worth for more than ten years in rough environments, including the automobile industry. They are used, for example, in storage systems, painting ovens, or immobilizers. The glass shell protects the transponder against dust, dirt and moisture. It is not affected by impacts or extreme temperatures. Transponders offer advantages over systems protected by key-operated switches or passwords, because they may be used more flexibly and are more user-friendly.

Access hierarchies increase safety

Multi-step access hierarchies for up to 16 levels can be easily configured using the RFID system, which distinguishes between master and user functions. For example, employees with master privileges may change system, program or header parameters, enable other masters or access the list of access privileges. The user function is limited to changing program parameters or resetting the counter. Users without a transponder can only read the control panel display.

The transponders are programmed with the code from a centralised programming station to assign the access hierarchies. Company and user data are equally transmitted to the transponders as are the user's name and personnel number. The matching data is stored in the reader, the so-called identification or PC module.

In addition to technical and production employees, Adam Opel AG also provided its maintenance teams with transponders. They also need to have access to the systems in order to perform regular maintenance duties.

The reader - a customer-specific solution from Sphinx Electronics

The transponder's counterpart, the read-write unit, also plays an important role. The Opel engineers pointed out right from the beginning that they wanted to use a standardised technology that is small in size and can be easily integrated into existing systems. Sphinx Electronics was awarded the contract for developing a customer-specific solution.

The read-write module has a special software program, which has been adapted to the production-specific needs and is capable of implementing different access hierarchies for most different pieces of equipment in the individual Opel factories all over Europe. The read/write module from Sphinx electronics is based on the Texas Instruments RFID technology. This technology is used in large numbers worldwide and has a proven record of absolute reliability in a wide range of different applications. When combined with specifically programmed software, it is highly versatile in use. External data exchange is ensured by a simple RS-232 interface. The read/write module from Sphinx Electronics is so tiny that it could be implemented into the control panel, for example, of the stud welding machines.

Complex performance data, low development cost

The new safety system will now be integrated step-by-step into all European manufacturing locations. Even the U.S. facilities are interested in the RFID system. In total, several thousand transponders and readers will be set up in the near future. Its complex performance data and low development cost were the decisive reasons for Opel to choose the RFID technology.

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