Omron AMR Proposal for Denso

DENSO (MALAYSIA) SDN. BHD.

SMART Manufacturing for Material Handling

OMRON Electronics Sdn. Bhd
Sales Division
Kent Goh

©2020 OMRON Corporation

Agenda

1. Omron at a glance
2. Customer Issue and Requirement
3. Omron Solutions
4. Product Benefits and Features
5. Omron Success applications
6. Proposal and Key considerations
7. Omron Support
8. Summary of Benefits

©2020 OMRON Corporation 2

Corporate Profile

OMRON is a global leader with over 28,000 employees operating
across 120 countries with over JPY 678 billion in sales

Employees Operating across Sales in FY19
countries
28,000 678JPY billion
120

As of March,31 2020
©2020 OMRON Corporation 3

Global industry strategy

Bringing innovation to manufacturing through automation to
enrich the lives of people all over the world

Vehicles Digital equipment Food products Social infrastructure
Motorization Rich dietary habits Social facility
Communication
revolution construction &
maintenance

©2020 OMRON Corporation 4

Technological Innovation

Expectations are growing for the application of new technologies
to solve the social challenges at manufacturing sites

AI IoT Robotics 5G

©2020 OMRON Corporation 5

General Market Trend

Industry trends and drivers affecting manufacturing and automation

Local production for Consistent worldwide “Ultra” high precision Growing shortage of
local consumption quality assurance assembly skilled workers

Rapid launching Consumer demands Surging labor costs in
of equipment startup driving need for flexible emerging countries

manufacturing

©2020 OMRON Corporation 6

General Market Trend

Impact of COVID-19 on the manufacturing industry
Highlighting manufacturing challenges resulting from COVID-19

Managing factories Pursuing further security and Ensuring employee safety in
dotting the globe safety at manufacturing secure and safe workplaces
products

©2020 OMRON Corporation 7

Market trend for electronic components demand

Demand for electronics component is expected to increase with 10% CAGR
until 2025. This is driven by the four key sectors of industry.

Automotive Electronics Mobile semiconductors Industrial IoT Communication
Infrastructure

Increasing global demand for Larger variety of products required to cater
electronics manufacturing processing for different industries. Carrier tapes have

material such as carrier tape to be different size and shape.

©2020 OMRON Corporation 8

Agenda

1. Omron at a glance
2. Customer Issue and Requirement
3. Omron Solutions
4. Product Benefits and Features
5. Omron Success applications
6. Proposal and Key considerations
7. Omron Support
8. Summary of Benefits

©2020 OMRON Corporation 9

Customer Manufacturing Issues

Automate the material transfer process

• QR marker process to MCE18, operator need to walk
76m X 54 times (4.1km/shift)

• Eliminate walking workload to balance good efficiency at QR
marker process

• Rapid deployment & safe for employees

Reduce Labor Dependent

• A big shortage of skilled labor for repetitive task
• Ergonomics (each trolley weight 10kg)
• Heavy material transfer posting hazardous risk

Target for improvement Qualitative

Qualitative Eliminate manual transfer walking
time for balancing workload
Lead time reduction & increase
OEE up to 0.5% (Model line:
MCE18)

©2020 OMRON Corporation 10

Application Requirement

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Requirement Summary

Objective
To Automate Material Transfer Process
between QR marker to MCE18

Requirement 1 Requirement 2 Requirement 3

Transfer cycle time: Eliminate inventory (Just-in-time) Eliminate operator walking
54 times per 12 hour shift workload
(13 minutes per trip)
OMRON Solution 2 OMRON Solution 3
OMRON Solution 1
LD Cart Transporter Conveyor top Solution
Semi Manual Solution (Direct loading into machine)
(with alarm function)
©2020 OMRON Corporation 12

Agenda

1. Omron at a glance
2. Customer Issue and Requirement
3. Omron Solutions
4. Product Benefits and Features
5. Omron Success applications
6. Proposal and Key considerations
7. Omron Support
8. Summary of Benefits

©2020 OMRON Corporation 13

Omron Solution 1 (Semi Manual Solution with alarm function)

Omron LD Series (Max Payload 90kg)

AMR Top View AMR similar isometric look

magazines
trolley

Carrier 1
Carrier 2

©2020 OMRON Corporation

Omron Solution 1 (Semi Manual Solution with alarm function)

Carrier B
(post)
Carrier
1 (pre)
Carrier
2 (pre)
MCE18 machine

Step 1 Step 2
1. System indicators trigger replenishment 1. Operator load the AMR with carrier &

function to operator trigger AMR for machine replenishment

©2020 OMRON Corporation

Omron Solution 1 (Semi Manual Solution with alarm function)

Carrier A MCE18 machine Carrier Wire-bond
(post) 1 (pre) machine A
Carrier
Carrier B 2 (pre)exchange
(post)

Carrier Carrier A
1 (pre) (post)
Carrier
2 (pre) Carrier B
(post)

Step 3 Step 4
1. AMR with loaded carriers move to 1. Operator swaps carrier and acknowledges

MCE18 machine, trigger buzzer and completion of tasks. AMR moves back to
awaits operator attendance. QR marker to complete delivery.

©2020 OMRON Corporation

Hypothesis of productivity improvement

Present Handling

Visual notification
for replenishment

76m X 2 trips = 152m

Human can push Manual transport Manual Operator working on
1 trolley per time carrier to exchange of other jobs
machine magazines

AMR Handling Notification for
replenishment auto*
Total elimination of
walking workload

AMR can transfer 76m Manual Operator working on
2 trolley per time exchange of
AMR transport magazines other jobs
carrier to
machine ©2020 OMRON Corporation

Omron Solution 2 (LD Cart Transporter)

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LD Cart Key Features

©2020 OMRON Corporation

Control of Cart Transporter

Omron’s AMR on-board user interface or via tablet.
• Monitor robot status like battery level & etc
• View alerts if robots need assistance
• View the on-going job & job que list
• Send robot to destinations

©2020 OMRON Corporation 20

LD Cart in Action

©2020 OMRON Corporation

Omron Solution 3 (Conveyor top Solution -Direct loading into machine)

Elevator
Conveyor

©2020 OMRON Corporation

Pros & Cons Analysis

Solutions

Solutions Solution 1: Semi Manual Solution Solution 2: LD Cart Transporter Solution 3: Direct Machine Loading
3 mins
Estimated Cycle time: No 5 mins 5 mins
(Target 13 mins per 2-way trip)
Eliminate inventory (JIT) No Yes

Eliminate Operator Walking Yes Yes Yes
Advantages
1. Fastest to execute 1. Mimic existing process 1. Full JIT can be achieved
2. Future upgradable to “Solution 3” 2. Fast to deploy 2. Good modular design for
3. Most cost effective
future expansion

Disadvantages 1. Loading & unloading depend on 1. Require new trolley 1. Must incorperate elevator
operator 2. Higher investment cost conveyor loading into SMT line

2. Interfacing with Nutek
conveyor

3. Longer time to execute
4. Higher investment cost

©2020 OMRON Corporation

Agenda

1. Omron at a glance
2. Customer Issue and Requirement
3. Omron Solutions
4. Product Benefits and Features
5. Omron Success applications
6. Proposal and Key considerations
7. Omron Support
8. Summary of Benefits

©2020 OMRON Corporation 24

Mobile Robot Milestone

©2020 OMRON Corporation 25

AMRs vs. AGVs

The difference is flexibility Automated Mobile Robots (AMRs) can
safely navigate without the use of floor
Automated guided vehicles (AGVs) magnets or wall-mounted beacons. An
require a predefined path to follow, AMR will first create a baseline map of
either a network of magnetic lines on a facility using built-in sensors, then will
the floor or beacons on the walls. So constantly detect its surroundings.
although AGVs allow modifications to When processes change, AMRs can
production lines, facilities will need to easily change as well, creating networks
install new equipment every time the of new routes or being reassigned to
AGV path is changed, leading to new tasks.
downtime and extra costs.

OMRON AMR AGV

Set Up Ready to go after Requires navigation guides
simple mapping
Navigation
Navigates autonomously and Needs guides, such asfloor Unlike autonomous mobile
Obstacles safely without physical guides magnets orbeacons robots (AMRs), automated
guides vehicles (AVGs) require
Map Change Safely avoids obstacles Stops at obstacles and guides, whichrestrict their
Changing without stopping remains still until obstacles options for routing.
Destinations are removed
Scalability
Easy Factory modifications

Easy Factory modifications

Easy Factory modifications

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Mobile Robot Product Range

©2020 OMRON Corporation 27

Easy Setup

• Self-Mapping, Self-Navigating

Step 1 - Map Step 2 – Set Goals ReCaudstyomtoerrBuunilt –Sosleutniodn jobs OMRON mobile robots are easy to get
up and running with minimal
programming and requiring no
construction such as the installation of
magnetic tape or navigation markers.
Easy integration with MES, ERP, and
WMS. Enhanced security to comply
with IT systems

▪ Simply drive the mobile robot
through your facility to gather map
data

▪ Mapping data is uploaded to the
mobile robot software

▪ In the software designate your
target locations and you are ready
to run.

©2020 OMRON Corporation 28

Safety

• Avoids static and moving obstacles
• Complies with ISO EN1525, JIS D6802 and ANSI B56.5 safety standards

OMRON’s patented side safety lasers
offer safety to not only protect the
robot but the load being carried and
possible equipment or people that
cannot be seen by floor level sensors.

Customer Built Solution

©2020 OMRON Corporation 29

Accuracy Positioning

• Stop Position Accuracy +/-8mm

Omron AMRs offer two solutions for
dependable and repeatable target
positioning

Cell Alignment Positioning System (CAPS)
CAPS evaluates real-world features to
effectively align robots for high accuracy
drop-offs and pick-ups.

High Accuracy Positioning System (HAPS)
HAPS allows our mobile robots to move
along fixed paths in applications that require
tight tolerances.

Customer Built Solution

©2020 OMRON Corporation 30

Fleet Management

• The Fleet Management running with FLOW Core software can manage fleets up to 100 robots

The OMRON Fleet Operations Workspace (FLOW)
solution provides an intelligent fleet management system
that monitors mobile robot locations, traffic flow, and
job requests, ensuring your factory operates at peak
efficiency. OMRON Fleet Manager can manage fleets of
up to 100 robots in any configuration

FLOW Core quickly and easily integrates with your
factory’s manufacturing execution system (MES) or
enterprise resource planning (ERP) solution. The
integration toolkit provided with FLOW Core connects
OMRON’s mobile robot fleet with any MES/ERP system
via industry standard RESTful, SQL or MQ APIs.

Customer Built Solution

©2020 OMRON Corporation 31

Fleet Management

JOB1 JOBS JOB2 JOB 3 JOB4
JOB1 JOB5 JOB5
JOB4

NEXT
JOB4

CURRENT
JOB1

Intelligent Job Assignment Managed Motion Traffic Control

Reduces wasted time and movement by Ensures smooth operations in busy environments Notifies converging robots of their predicted paths,
continuously looking ahead to anticipate which by coordinating traffic flows and efficiently allowing them to re-calculate and avoid collision in
robots will be best positioned for upcoming tasks. sequencing pick-up and drop-off at target the most efficient way.
locations.

Customer Built Solution

©2020 OMRON Corporation 32

Fleet Management

DESTINATION DOCKING STATION Skill Administration
ADDED
Charge Management Understands the capabilities of each vehicle in the
REVISED fleet, and always makes sure that the right job is
FLOORPLAN Tracks battery power of the entire fleet, directing assigned to the right robot.
robots to their nearest available, or preferred,
Automatic Updates docking station on a schedule that ensures
Performs map, navigation, and job updates continuous fleet operation.
automatically across the entire fleet

Customer Built Solution

©2020 OMRON Corporation 33

Clean Room & ESD Compliance

©2020 OMRON Corporation 34

Agenda

1. Omron at a glance
2. Customer Issue and Requirement
3. Omron Solutions
4. Product Benefits and Features
5. Omron Success applications
6. Proposal and Key considerations
7. Omron Support
8. Summary of Benefits

©2020 OMRON Corporation 35

Omron AMR Success Story Denso

Collaborative mobile robotics taken to the next level in intelligence

Omron AMR Success Story Denso

Collaborative mobile robotics taken to the next level in intelligence

Omron AMR Success Story Omron electronics

Collaborative mobile robotics taken to the next level in intelligence

Omron's factory in Shanghai is creating
an environment where people and
robots work together, to meet
challenges in manufacturing today,
improving operator productivity and
overall equipment effectiveness (OEE).

Omron AMR Success Story Omron electronics

Collaborative mobile robotics taken to the next level in intelligence

https://www.youtube.com/watch?v=naESfMwWs44

Omron AMR Success Story Skoda Automotive

Collaborative mobile robotics taken to the next level in intelligence

The robot completes 120 trips per day and travels a total
distance of 35 km on its route between the mechanical
measuring center and the processing machines. The testing
and pilot phases have already been completed; the robot is in
regular use at the factory starting from June 2018.

The increasing production numbers at ŠKODA AUTO translate
into higher utilized capacity for the plants and more traffic in
the production areas. The autonomous robot contributes to
the continuous improvement of work safety in Skuda Auto
and helps to minimize work risks.

Omron AMR Success Story Skoda Automotive

Collaborative mobile robotics taken to the next level in intelligence

https://www.youtube.com/watch?v=UUaBOMCSjdU

Omron AMR Success Story CresTek

Collaborative mobile robotics taken to the next level in intelligence

CesTek Automation complete a customer project
with a total of eight fleet managed autonomous
mobile robots as well as conveyors for product
reception and delivery. The robots are capable of
handling delivery of components as well as
reception of finished products in a factory with a
high bay warehouse and approximately 50 work
stations.

The robots shown in this project are Omron LD-60
retrofitted with proprietary double conveyers on
top. Each robot is capable handling a total payload
of 60 kg with a top speed of 1.8 m/s. The conveyors
on top can receive and deliver products at a speed
of 0.5 m/s. In the given setup this gives the
complete system a capacity of 250 boxes per hour.

Omron AMR Success Story CresTek

Collaborative mobile robotics taken to the next level in intelligence

https://www.youtube.com/watch?v=WtFH2_Xwgw8

Omron AMR Success Story Bosch

Collaborative mobile robotics taken to the next level in intelligence

Application: Transportation of SMT materials

Parts: Spare parts of automotive

Robots involved: LD90 x 3

Overview of customer process:

1. LD transport the magazine from the storage area
to SMT line.

2. The LD automatically takes out the magazine
from the storage location by the conveyor, drops
it to the magazine stocker at the end of the SMT
line, and at the same time it automatically
retrieves the empty magazine and returns it to
the storage place.

Agenda

1. Omron at a glance
2. Customer Issue and Requirement
3. Omron Solutions
4. Product Benefits and Features
5. Omron Success applications
6. Proposal and Key considerations
7. Omron Support
8. Summary of Benefits

©2020 OMRON Corporation 45

Budgetary Cost [Solution 1 - Semi Manual Solution ]

No. Main Equipment Qty
1
1 LD90 AMR (90kg payload)
2 Enterprise Manager Not inclusive (Single robot no need)
3 WIFI infrastructure Not inclusive (Single robot no need)
4 Control Components which include PLC, touch screen & etc
1 lot
5 Mechanical structure , buzzer & etc 1 lot

6 Site installation & commissioning: 1 lot
a) Programming: AIV Mapping work, Dropoff & Pickup points programming
b) 3 days training

Budgetary Cost will be provided separately

©2020 OMRON Corporation 46

Budgetary Cost [Solution 2 – LD Cart Transporter]

No. Main Equipment Qty
1
1 LD130-CT Cart Transporter AMR
2 Enterprise Manager Not inclusive (Single robot no need)
3 WIFI infrastructure Not inclusive (Single robot no need)
4 Customized trolleys
X units
5 Site installation & commissioning:
a) Programming: AIV Mapping work, Dropoff & Pickup points programming 1 lot
b) 3 days training

Budgetary Cost will be provided separately

©2020 OMRON Corporation 47

Budgetary Cost [Solution 3 – Direct Machine Transfer Solution ]

No. Main Equipment Qty
1
1 LD90 AMR (90kg payload)
Not inclusive (Single robot no need)
2 Enterprise Manager Not inclusive (Single robot no need)

3 WIFI infrastructure 1 lot
1 lot
4 Control Components which include PLC, touch screen, interface with receiving
conveyor & etc 1 lot

5 Mechanical interface:
1) Conveyor on AMR
2.) Elevator conveyor and etc

6 Site installation & commissioning:
a) Programming: AIV Mapping work, Dropoff & Pickup points programming
b) 3 days training

Budgetary Cost will be provided separately

©2020 OMRON Corporation 48

Cost Benefit Analysis

Tangible benefits Intangible benefits

• Reduced number of operators on site • Reduced risk of accidents or injuries involving
• Reduced machine idle time human operators
• Increased overall efficiency and productivity of plant
• Increased capability to monitor production data • Reduced risk of mistakes by operators
• Strengthen Denso brand as an adopter of advance
through traceability solutions
automation in manufacturing

©2020 OMRON Corporation 49

Agenda

1. Omron at a glance
2. Customer Issue and Requirement
3. Omron Solutions
4. Product Benefits and Features
5. Omron Success applications
6. Proposal and Key considerations
7. Omron Support
8. Summary of Benefits

©2020 OMRON Corporation 50