Volkswagen dramatically improves process monitoringMission Shanghai-Volkswagen controls the production process of every single car via a barcode label attached to each vehicle. To ease work and prevent delays in their production process, Volkswagen searched for a reliable verification system to match their existing scanner control system. Solution Axis network cameras were installed as part of a system created by German SeeTec and Industrielle Automatisierungssysteme. The camera monitors any errors and sends the image of the scanner to an Emergency Data Entry PC. To ensure that all components of the security system work properly, a flexible camera management software was also integrated. Result Employees save time by not having to physically go to cars to reread their barcodes. Volkswagen's just-in-time production process was considerably improved. The visual verification system is tailor-made for the existing technical configuration, and increases the value of the network at Volkswagen. Scanner system controls manufacturing process Since mid May 2000, Shanghai-Volkswagen has manufactured the business version of its "Passat" in a newly built factory in Anting, about 50 km out of Shanghai. After initial manual material-flow controlling they implemented a control system for their production. This system also handles the orders for just-in-time suppliers. The control system is connected to local Pcsystems supplied by ICS Industrielle Automatisierungssysteme GmbH in Germany. Volkswagen controls the production process of every single car via a barcode label that is attached to each vehicle. These barcodes are read by scanners installed at certain points along the assembly line, and the data is transmitted via the intranet into the control system. An error read by a scanner meant that an employee would have to re-read the barcode directly at the respective car and enter the data into a PC. Visualise the error and act remotely To ease work and prevent delays in the manufacturing progress, SeeTec Industry Monitoring GmbH and ICS  Industrielle Automatisierungssysteme GmbH developed a visual verification system with an Axis network camera as a key element. Once the scanner has read an error, the reading system "Data Collection Point" (DCP) sends a signal to the camera, which then automatically forwards a picture of the barcode label to the Emergency Data Entry PC (EDE) via the intranet. The Axis network camera is equipped with a high focal lens to ensure the complete label is viewed. The implemented Viewpoint software from SeeTec opens a window on the screen and views the label. An employee then copies the numbers into a second window from where data is directly transmitted to the control system. In case of inadequate light sources for the camera at night, the DCP system automatically turns on light via the Interbus S I/O. Reliable system with video management software In order to be able to provide a fully comprehensive solution, a self-test routine was incorporated into the system - the Viewpoint software recognises spelling errors and rejects them, so that only after the correct entry is found will the barcode be forwarded. Furthermore, a protocol converter was installed to allow the transfer of pictures from the camera to the Data Collection Point. Finally, there was one vital question that needed answering: how to make sure that all components of the system will work reliably? To solve this, a signal circle was created. In short intervals, the Data Collection Point sends out a signal, which travels between all components of the system, and should the signal not be registered and answered by any of the components within a determined time frame, a warning is created. The warning appears either as an acoustic message or on the screen. The installed system is a smart combination of software and technology. It does not only use existing network capabilities, thereby saving money for the implementation of new ones, but also saves a considerable amount of time for employees involved in production, and subsequently is an important contribution to the just-in-time production process at Volkswagen. | 
