With manufacturers moving towards digitisation and smart factories, Jendamark is transforming the way production lines function through Odin Workstation.
What is Odin Workstation?
Odin Workstation interacts with the tools, equipment and PLC associated with the line to record and store data, which is used for generating reports on various aspects of production.
Some of the key components of Odin Workstation are:
- Operator guidance: This system displays all the information regarding the processes to be followed along with pictorial representations, special notes, parts and tools to be used. Making life easier for operators, this is a paperless production process.
- Line diagnostics: The diagnostic tool helps maintenance managers to check the status of all the tools, devices and equipment for a quick diagnosis of issues that arise during production. It provides information like time logs, real-time values of sensors, communication data etc.
- Process deviations: Process deviations allows line supervisors to handle process-related deviations such as sending a part to rework, skipping processes, entering barcodes manually and re-doing processes.
- Tool positioning: Tool positioning helps to assign indicators wherever there is a process need for sequential tightening of bolts. With the help of images and these indicators, the operator can follow the sequence and perform the operation.
- Device communication: Device communication provides information about all the devices communicating with Odin Workstation and whether there is an issue with any of the devices.
Who was Odin Workstation created for?
Odin Workstation is designed to be a user-friendly solution for end users such as operators, line supervisors, production managers and maintenance managers.
Is Odin Workstation already in use?
Odin Workstation was first implemented on the Audi engine assembly line at the Skoda facility in Aurangabad. With the engine being such a critical component with complex assembly processes, Odin Workstation was able to cater to all the needs of the customer and help them produce quality products.
Operators could build the engine with ease with the help of the worker guidance system by selecting the right parts and tools, and following the defined processes. It led to fewer errors and ensured process poka-yokes (Japanese: ‘mistake-proofing’). Maintenance team could easily find issues that came up during production using the diagnostic tool, thereby reducing overall downtime.
Odin Linewatch is a Jendamark software solution that delivers real-time production data straight from your assembly line. Get the information you need to make the right decision at the right time and manage production problems before they happen.
This smart Andon system displays all the data you need as it happens on an easy-to-read dashboard. At the end of each shift, Linewatch sends an email summary of these key parameters:
- Production target
- Shift progress and time
- Productivity chart
- Machine performance
- Product quality
- System uptime
- Yield with respect to variant
- Shows attention-grabbing information first
- Exposes abnormalities in your production processes
- Presents actual status in rapid and simple way
- Quick interaction with user
- Provides all necessary information to analyse and optimise production
Screen 1: Example main screen
The main screen shows:
- The target set by Supervisor
- Monthly target
- Shift target
- Present target – automatically calculated by the cycle time set in the system
- Achieved – automatically calculated by system when part rolls off the line
- Rejection – if part is rejected on the line, it is automatically updated
- Shift progress bar
- Progress of the shift and system up time is shown in pie chart and bar graph
- Downtime, if any, initiated by the supervisor or not, is captured by the system
- Pre-defined breaks can also be shown in the progress bar
- Productivity graph and pie chart for productivity, quality and system up time
- Shows OEE graph with all the parameters
Screen 2: Example main screen
This screen shows:
- Line-specific inventory pile-up details
- With visual colour variation for triggering the supervisor for abnormal production rate i.e. low or high production
- Sub-assembly inventory pile-up details
- With visual colour variation for triggering the supervisor to re-access the production and add parts, or stop in case of excess production
- EOL testing details and inventory pile-up
- FPY for every variant
Please contact the Jendamark India team if you would like to know more.
With the Indian government offering attractive incentives to electric vehicle (EV) buyers, Jendamark India is rapidly becoming a trailblazing player in the country’s quest for cleaner energy.
India’s proposed EV incentive scheme is set to offer significant tax breaks for consumers on the road to achieving a targeted 30% share of all new vehicle sales by 2030.
“Our government is really pushing this issue,” says Jendamark India’s CEO, Himanshu Jadhav. “To achieve this, the government is planning to reduce general sales tax on EVs from 12% to 5%. A few months ago, it was reduced to 12% from 18%.”
Another proposal already implemented is that those buying electric vehicles will receive an additional income tax deduction of Rs 1,50,000 on the interest paid on loans taken to buy electric vehicles.
As a result, he says, buyers are warming to the idea of this new vehicle technology.
“According to a recent survey, 50% of car buyers in India are ready to switch to EVs if the infrastructure is available.”
But, incentives aside, the global population in general has a growing awareness of the need to go green.
“Awareness and sensitivity towards climate change and pollution issues is a hidden force for the surge in EV market. Every individual globally wants to reduce his or her carbon footprint,” says Jadhav.
This burgeoning market has seen original equipment manufacturers (OEMs) in India venturing into and ramping up their EV production, which has had a knockon effect for suppliers forced to embrace these new technologies.
Jendamark India has been at the leading edge of these industry developments, designing and building the first battery pack and power electronics assembly line in the country for Mahindra Electric Mobility Ltd.
Power electronics consist of a charger, variable frequency drive and all electrical signal processors which power the vehicle, whereas a power pack is a cluster of batteries put together as a pack which powers the vehicle.
“Battery pack assembly is new technology in India and local equipment manufacturers are not available for EV manufacturers in India, so we have had to depend on European and Chinese equipment suppliers,” Jadhav explains.
“However, Jendamark has invested strongly in the research and development, design and manufacturing of such equipment in India. Our Industry 4.0-enabled assembly lines are helpful in increasing production and lowering the manufacturing cost of battery packs that fit in EVs.”
In fact, battery costs are expected to be cut by half while performance is expected to double over the next decade.
Jendamark’s global head office in South Africa has played an integral role in the design process for Jendamark India’s first EV power pack assembly lines, providing the benefits of its three decades of automotive expertise where needed.
“Following the design phase, we recently built and supplied two assembly lines, both manufactured in India, and are in the process of executing an expansion project for the addition of new variants on the existing lines,” says Shashikant Chaudhari, who was Jendamark India’s management representative on this project.
The human component has also not been overlooked when it comes to technological development.
“Batteries being assembled carry charge. Human safety is very important when you handle charged batteries. Using Jendamark’s own digital manufacturing software, Odin, we monitor and instruct operators in following right assembly sequence to ensure their safety.“
While venturing into new territory has had its challenges, Chaudhari says it has been an exciting journey so far.
“Jendamark is an expert in powertrain solutions for internal combustion vehicles, while EVs have a completely different powertrain. But EVs have brought us tremendous new learning opportunities.”
FACT BOX: CLEARING THE FOG
At the heart of India’s push towards EVs is the government’s all-important clean energy policy aimed at reducing toxic pollution levels.
- Severe traffic congestion in India’s major cities can result in average trip speeds of less than 20 kilometres per hour.
- At such speeds, vehicles emit four to eight times more than they would under less congested conditions.
- Vehicles also consume more fuel per trip and produce a higher carbon footprint due to congestion.
- According to the website India Today, on Diwali night 2019, many areas of Delhi recorded an Air Quality Index of 999 – 16 times higher than the prescribed limit.
Jendamark’s virtual reality room allows designers and customers to explore the possibilities of a new production line in three-dimensional reality via an interactive, computergenerated experience.
The introduction of virtual reality (VR) has had tangible, real world benefits for Jendamark customers by enhancing the design review process.
First, the design team makes the complete production line in VR and a member dons the glasses for a walkthrough of the line. This simple step often highlights potential flaws that would not be apparent during a normal design review.
“It’s about seeing the design with fresh eyes,” says Yanesh Naidoo.
“For example, from a maintenance perspective, can the motor be easily replaced or is it stuck underneath in an unreachable back corner? And, as the operator, can one easily reach all the components, and does it really take the time predicted?”
Naidoo says VR is ideal for ironing out any kinks before the design is handed over to manufacturing and for clients to get a better understanding of its workings before sign-off.
“While the line is in production, VR could also be used to train teams of operators on the virtual version, so that they are ready to hit the ground running when commissioning is complete.”
The Internet of Things (IoT) describes a network of machines, devices and other items that have built-in connectivity, electronics, software or sensors that allow them to share data and improve efficiency for humans interacting with them.
While the idea of a “smart home” or “smart business” may seem far in the future, current estimates suggest that there could be around 30 billion connected devices worldwide by 2020.
For Jendamark, the first application of IoT principles will soon be demonstrated with the addition of a documentation app* to its Odin software platform.
According to Yanesh Naidoo, it is standard practice for the company to deliver all the printed manuals and necessary documentation for a new machine or line as part of the handover process to a customer. Unfortunately, those documents are often misplaced over the years and remain unread until something goes wrong, he says.
“Our solution is to place a 2D matrix or QR code on the main sub-assembly of every machine we make. Then, instead of trying to find the manual, the maintenance technician simply scans the code using the app, which will take him to a link with the correct documentation for that particular sub-assembly.”
Taking this one step further, the IoT could be used to collect data such as the part numbers on a customer’s machine as well as the replacement parts available in his or her storeroom. This information would be available at a glance via the app, thus reducing machine downtime while fixing the problem.
* Currently in development. Available soon for Android devices from the Google Play store.