MotionFab Limited

CA

-Microcontroller development and implementation using IAR Development Suite into health care products. -Soft PLC, Human Machine Interface,. Net development of control systems and enhancements. -CNC turing and machining of precision parts with quality inspection and assembly in a variety of materials. -Electrical, Mechanical and software design of turn-key solutions.

MotionFab services and manufacturing expertise can provide solutions to multiple industries. Our diverse experience allows us to build and integrate complete solutions with follow up support. MotionFab continues to provide quality and cost effective custom business solutions with improved productivity.

Companies range with small automation projects and precision machining fabrication to complex prototyping and system development. Motionfab continues to gain familiarity of high new innovative industrial engineering products from suppliers which makes us capable to provide solutions from low level microcontroller to Soft PLC SCADA Systems, circuit boards to electrical panels, or precision machined parts to automated turn-key solutions.

MotionFab respects clients with company policies and privacy in-regards to external company references; therefore, please contact MotionFab directly for customer listing.

Wal*Mart Optical

Wal*Optical is a lens manufacturing company for the ophthalmic industry specificaly to the affiliated Wal*Mart Stores.

Wal*Mart contains multiple manufacturing lines for lens processing. A particular system, UL60, is a complex intergrated automation system which allows one operator to produce lenses through the blocking, cutting, polishing and coating process. Compared to the convetional equipment which can take 6 to 7 personnel with limited throughput, the UL60 is the primary focus at Wal*Mart encompasing over 60% of the labs production.

The system is actually divided into 5 processing stations with automated material handling pick and place system in-between, enclosed in one structure. The processing station are: Blocking, Roughing, Finishing, Polishing and Coating. Each processing station contains from 2 axis of controlled motion to 5. Pneumatic actuators, Hydrolics, Inverters, electrical/servo/stepper motors, pneumatics/electrical I/O, barcode readers, RFID readers, live video imaging system, UV light/compund dispensing and curing system as well as custom engineered devices.

In order to ramp up production, MotionFab and Wal-Mart analysed the manufacturing equipment and process to produce a stratgey that would allow increased throughput. The areas of improvement were: System reliability, System physical speed, Operator/System efficency, and manufacturing process.

The system reliability posed a problem in production downtime from hardware repairs, software bugs and end-product quality. MotionFab reviewed the system and produced a failure listing prioritied by mean-time-to-repair and cost analysis. MotionFab determined one of the major problems was problem determiniation. Technicians effieciently determining where the problem occured and area to troubleshoot. Other areas varied from control logic errors to hardware mechanical design issues. The following were some of the corrective actions:

MotionFab redesigned the error and reporting for the system to point technician more effectivly in the problematic area. Motionfab also developed some utilities to help log and effecivley diagnose interrupts with statistics. MotionFab also provided readlity available parts in the high wear rate components in close locations by 24 hour depots. This minimised the lead time to get components to the customer and installed. Preventative maintenance schedules and actions were reviewed to ensure optimal operating conditions. The control logic error were addressed and deliverd as part of the software package and install along with process improvements. The control logic changes also affected I/O. New schematics and electrical panel layouts were designed. The system speed was analysed to determine the subsystems and manufacturing process 'bottle-neck'. A review of the system allowed MotionFab to provide a solution to the process in motion control speeds as well as process engineering.

The operator job functions were to queue up jobs as well as initially inspect the end produce quality. MotionFab determined to improve the operator abilities was to improve the time the operator has to perform the functions. Motionfab redesigned the HMI specific to the operators needs with orientation and moving multiple atonimc actions onto one. Technical Personnel would access security controlled screens for troubleshooting and preventative maitenance.

Manufacturing process was reviewed and utilities developed to aid Wal-Mart in determining future analysis. production statitics and failure mode analysis automated from the data collected from the system. These were custom designed and developed for the system.

MotionFab developed the changes off-site and tested in simulation. MotionFab backed-up all configurations and system information for completion of a back-out plan if needed. MotionFab scheduled with Wal*Mart the upgrades and combined both software and hardware changes simintanously to minimise production interruption. MotionFab tested the intial system and followed through with the other system upon satisfactory realization of the changes.

Manufacturing Equipment -Nakamura-Tome SC150/SC-150M Turing Centre -Gage Block Set -Matsuura MC-600 VF Machining Centre -Starrett HB400-2 Optical Comparator -Automatic Horizontal Bandsaw -BHMJL Olympus Metallurical Microscope -Millermatatic 250X Heidenhein -PWM 8 Diagnostic Set -Benato Manual Lathe Tektronix -THS730A Digital Scope -First Manual Mill Starrett -Surface Plate -Nakamura-Tome SC250/SC-250M Turing Centre -Mitutoyo Electronic Height Gauge -Zygo New View 100 Scanning White Light Interferometer -Nettest 11 (Profibus Testing tool) -Vermont Gage Pin Set

Moncton, New Brunswick; Columbus, Ohio; Dallas, Texas;

332710, 541330, 541420, 541510, 541510