Based on an existing production line, Huub Camp explains the different phases to transform a basic production setup into a nearly blue-light factory line.

1. From pilot stations
towards flexible
mass production lines
Huub Camp
May 10th, 2011

2. Content
- Introduction
- Six levels of mechanization in a historical context
- Six levels of automation for new products
- A LEVEL 6 example
- How to make the difference in the future in Western Europe
Confidential May 10th, 2011 2

3. - 1980-1986 Technical University Eindhoven (Mechanical engineering)
- 1987-1994 Philips Lighting Eind. (Equipment & System Engineering)
(engineer , sr. engineer , project leader/architect)
- 1994-1995 Philips Lighting Turnhout (Mechanization department)
(group leader, architect, account manager)
- 1995-2000 Philips Lighting Terneuzen (Mechanization department)
(department manager + customer relation)
- 2000-2004 Assembleon Eind. (pick & place equipment ) (owned by Philips)
Program & BU manager feeding systems
- 2004-now Philips Lighting Turnhout : Global Technology Development
Mechanization
- 2004-2007 Progam manager DPL (digital projection lighting)
- 2007-2009 Program manager new business development LED/OLED
- 2009-2011 Program manager EXTERNAL business development
Confidential May 10th, 2011 3

4. Started in 1891 with the production of incandescent lamps
Lighting
Consumer Lifestyle
Healthcare
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5. GTD MECHANIZATION
Link between Product Development and Production
PRODUCT DEVELOPMENT GTD MECHANIZATION PRODUCTION
Confidential May 10th, 2011

6. Number of equipment and process FTE
GTD MECHANIZATION Turnhout :
Roosendaal:
95 FTE
65 FTE
Aachen : 80 FTE
Global Network Eindhoven Pila : 40 FTE
Netherlands Shanghai : 35 FTE
Roosendaal Others : 15 FTE
Pila
Netherlands Poland
Shanghai
Turnhout China
Belgium
Aachen
Germany
Bangpoo
Thailand
Surabaya
Indonesia
GLOBAL TECHNOLOGY DEVELOPMENT MECHANIZATION
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7. Six levels of mechanization in a historical context
Level 1 - maximum manual
- quality <->craftsmanship
Confidential May 10th, 2011 7

8. Six levels of mechanization in a historical context
Level 1 - maximum manual
- quality <->craftsmanship
Level 2 - some process tools/workstation
- quality <->craftsmanship
Philips glass factory
1916
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9. Six levels of mechanization in a historical context
Level 1 - maximum manual
- quality <->craftsmanship
Level 2 - some process tools/workstation
- quality <-> partly craftsmanship
Level 3 - coupled workstations
- quality<->partly craftsmanship
- handling manual
Philips 1920
Confidential May 10th, 2011 9

10. Six levels of mechanization in a historical context
Level 1 - maximum manual
- quality <->craftsmanship
Level 2 - some process tools/workstation
- quality <->partly craftsmanship
Level 3 - coupled workstations
- quality<->partly craftsmanship
- handling manual
Level 4 - first coupled machines
- quality<->process automated
- automated transport
Philips 1934
Confidential May 10th, 2011 10

11. Six levels of mechanization in a historical context
Level 1 - maximum manual
- quality <->craftsmanship
Level 2 - some process tools/workstation
- quality <->craftsmanship
Level 3 - coupled workstations
- quality<->craftsmanship
- handling manual
Level 4 - first coupled machines
- quality<->process automated
- automated transport
Level 5 - multi product type lines
- process automated + control (scada)
- optimized buffers
Weert :incandescent early 60 (speed 2000/hour)
70’s and 80’s speed increases up to 5000/hour
Roosendaal: TL (speed HOR 2000) late 60’s
70’s and 80’s HOR 3000 and HOR 6000
90’s speed increases to 7200/hour
Confidential May 10th, 2011 11

12. Six levels of mechanization in a historical context
Level 1 - maximum manual
- quality <->craftsmanship
Level 2 - some process tools/workstation
- quality <->craftsmanship
Level 3 - coupled workstations
- quality<->partly craftsmanship
- handling manual
Level 4 - first coupled machines
- quality<->process automated
- automated transport
Level 5 - multi product type lines
- process automated + control (scada)
- optimized buffers
Level 6 - flexible lines (many product types)
- control 6 sigma (Scada +MES+ERP)
- Central Control Room (lean)
Confidential May 10th, 2011 12

13. Six levels of automation for new products
Level 1 - maximum manual Product developer makes first of
- quality <->craftsmanship a kind
Level 2 - some process tools/workstation GTDM develops first process
- quality <->partly craftsmanship tools and process for proto serie
Level 3 - coupled workstations GTDM develops 6 sigma robust
- quality<->partly craftsmanship process on pilot equipment
- handling manual
Level 4 - first coupled machines GTDM designs/build a low speed
- quality<->process automated line.
- automated transport
Level 5 - multi product type lines GTDM designs/build a high speed
- process automated + control (scada) line.
- optimized buffers
Level 6 - flexible lines (many product types) Line improvements + additional
- control 6 sigma (scada +MES) product types
- Central Control Room (lean)
Confidential May 10th, 2011 13

14. A LEVEL 6 example
Huub Camp
May 10th, 2011
Central Control Room

15. Eindhoven
Turnhout
Road Map
DP866
High • 7lbs, FSC / SCR Engine
Confidential May 10th, 2011 15
DP757
• 6.6lbs, 2100L(Min • 0.7” XGA 12D DDR / LVDS DMD 15
• 2200 (min. 2000)/ 3000L(min 2400L)

16. siub retemaid egidnewnI K tkudorp etgneL L rof sretemaraptcudorP 30' iem 31 3.1 V
elacS
+ egidnewni muminiM G .xam xD H )nevob / redno lihcsreV( etaD noisreV
16 May 10th,emaN tinU
2011 Confidential
L atleD I )wtiu / wni gniviuhcsreV( siub retemaid egidnewtiU J sblub depahs PHU
KIR E )ruotnoK egidnewnI laaRts( taam 521 F
rof sretemaraptcudorP 30' iem 31 3.1 V
+ egidnewni muminiM G .xam xD H )nevob / redno lihcsreV( 5.2 5.2 etaD noisreV
- & + etkiddnaW 2/1C lob drooK D
)ruotnoK egidnewnI laaRts( KIR E taam 521 F
retemaid egidnewtiU A retemaid egidnewnI B
Main goal : 8FTE  4FTE
5.2 5.2
- & + etkiddnaW 2/1C lob drooK D
H
retemaid egidnewtiU A retemaid egidnewnI B
+/- 200+ Lamp types
H
+/- 50 Burner types
G A B K J
E
G A B K J
1C E
2C
I
1/01 1C 2C
elacS I
D
GEOMETRIEMETING POSITIE 12 MET VISION 2 CAMERA 2 2 AREMAC 2 NOISIV TEM 21 EITISOP GNITEMEIRTEMOEG
1/01 0.5
E I I E
B B
C D HH D C
FG GF
elacS
A A
D
J J
M1: (A – C) = AFWIJKING MIDDEN MO-BAND T.O.V. MIDDEN KLEMVEER ( kant klemveer ). .) reevmelk tnak ( REEVMELK NEDDIM .V.O.T DNAB-OM NEDDIM GNIKJIWFA = )C – A( :1M
M2: (A – D) = AFWIJKING MIDDEN MO-BAND T.O.V. MIDDEN KLEMVEER (kant elektrode ). 0.5 K K .) edortkele tnak( REEVMELK NEDDIM .V.O.T DNAB-OM NEDDIM GNIKJIWFA = )D – A( :2M
Met M1 en M2 kan men de symmetrie en scheefstand van de Mo-band berekenen. .nenekereb dnab-oM ed nav dnatsfeehcs ne eirtemmys ed nem nak 2M ne 1M teM
M3: (D – F) = AFWIJKING MIDDEN BALK T.O.V. MIDDEN MO-BAND (kant mo-band). .)dnab-om tnak( DNAB-OM NEDDIM .V.O.T KLAB NEDDIM GNIKJIWFA = )F – D( :3M
F
Zuiger
regiuZ
M4: (D – G) = AFWIJKING MIDDEN BALK T.O.V. MIDDEN MO-BAND (kant elektrodekop). L .)pokedortkele tnak( DNAB-OM NEDDIM .V.O.T KLAB NEDDIM GNIKJIWFA = )G – D( :4M
Met M3 en M4 kan men de symmetrie en scheefstand van de elektrode berekenen. .nenekereb edortkele ed nav dnatsfeehcs ne eirtemmys ed nem nak 4M ne 3M teM
M5: (B – E) = LENGTE MO-BAND DNAB-OM ETGNEL = )E – B( :5M
M6: (E – H) = UITSTEEKLENGTE ELEKTRODE EDORTKELE ETGNELKEETSTIU = )H – E( :6M
M7: (I – J) = DIKTE ELEKTRODEKOP POKEDORTKELE ETKID = )J – I( :7M
.DNAB-OM NEDDIM .V.O.T POKEDORTKELE ED NAV TNUP ED NAV NEDDIM GNIKJIWFA = )H – D( :8M
F
GEOMETRIEMETING POSITIE 12 VAN DE PUNT VAN DE ELEKTRODEKOP T.O.V. MIDDEN MO-BAND.
M8: (D – H) = AFWIJKING MIDDEN MET VISION 2 CAMERA 2
M9: (K – E) = AFSTAND VAN ZUIGER TOT ONDERKANT MO-BAND I
DNAB-OM TNAKREDNO TOT REGIUZ NAV DNATSFA = )E – K( :9M
E
M10: (K – H) = AFSTAND VAN ZUIGER TOT EINDE ELEKTRODEKOP POKEDORTKELE EDNIE TOT REGIUZ NAV DNATSFA = )H – K( :01M
L
B
C D H
A FG
J
M1: (A – C) = AFWIJKING MIDDEN MO-BAND T.O.V. CAMERAKLEMVEER ( kant klemveer ).
GEOMETRIEMETING POSITIE 7 MET VISION 2 MIDDEN 1 1 AREMAC 2 NOISIV TEM 7 EITISOP GNITEMEIRTEMOEG
M2: (A – D) = AFWIJKING MIDDEN MO-BAND T.O.V. MIDDEN KLEMVEER (kant elektrode ). K
Zuiger
regiuZ
Met M1 en M2 kan men de symmetrie en scheefstand van de Mo-band berekenen.
M3: (D – F) = AFWIJKING MIDDEN BALK T.O.V. MIDDEN MO-BAND (kant mo-band).
M M
Zuiger
M4: (D – G) = AFWIJKING MIDDEN BALK T.O.V. MIDDEN MO-BAND (kant elektrodekop). N N
Met M3 en M4 kan men de symmetrie en scheefstand van de elektrode berekenen.
M5: (B – E) = LENGTE MO-BAND
L L
MA: (L – N) = AFSTAND VAN ZUIGER TOT ONDERKANT MO-BAND
M6: (E – H) = UITSTEEKLENGTE ELEKTRODE DNAB-OM TNAKREDNO TOT REGIUZ NAV DNATSFA = )N – L( :AM
M7: : (L – M) DIKTE ELEKTRODEKOP TOT BOVENKANT MO-BAND
MB (I – J) = = AFSTAND VAN ZUIGER DNAB-OM TNAKNEVOB TOT REGIUZ NAV DNATSFA = )M – L( : BM
M8: (D – H) = AFWIJKING MIDDEN VAN DE PUNT VAN DE ELEKTRODEKOP T.O.V. MIDDEN MO-BAND.
M9: (K – E) = AFSTAND VAN ZUIGER TOT ONDERKANT MO-BAND
M10: (K – H) = AFSTAND VAN ZUIGER TOT EINDE ELEKTRODEKOP
GEOMETRIEMETING POSITIE 7 MET VISION 2 CAMERA 1
Zuiger
M
N
DPL Burner production
L
MA: (L – N) = AFSTAND VAN ZUIGER TOT ONDERKANT MO-BAND
MB : (L – M) = AFSTAND VAN ZUIGER TOT BOVENKANT MO-BAND
DMAIC

17. Pre MEDIC
BP 2007-2010  Lean focus
Q 1 2007 Q 1 2009
Confidential
Main goal : 8FTE  4FTE
May 10th, 2011 17

18. MEDIC
WHat
Design of control room How
Machine Product
Visuele Process
Situation Inspection adjustments
operation progress
control room
coupling with Visualisation
Eyes on the line Manuals
machine control proces
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Confidential May 10th, 2011

19. GTD MECHANIZATION TURNHOUT
Way of working
Concept Specification Engineering Realization Service
 Product co-  Industrial Setup  Mechanical,  Global sourcing  Product range &
development  Manufacturing electrical and  Assembly capacity
 Research process software design  Start & ramp up extension
 Feasibility development  Training
 FEM analysis  Productivity
studies  Design for Six  Repeats
 Concept creation Sigma  System improvement
 Consulting  Design for integration  Spare parts
 Lean solutions manufacturing  Project management
 Industrial  Prototyping management  Relocation
Efficiency studies  CE - Safety  Industrial
 Concept freeze  Ergonomics Efficiency
 Industrial Quality
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20. MEDIC
Pilot CCR CCR
• Flexible • Fixed way of working
• Maximal control • Only essential controls
• Low cost testing • Robust
• NO production disturbance • Simple/friendly to operate
20
Confidential May 10th, 2011

21. MEDIC
Definine and discripe the CCR hardware
Control
server Central Control
Image
Room
server
Fabrieksnetwerk
Data
server
Machine 1 Machine X
21
Machine Rand Machine Rand
Camera Camera
besturing apparatuur besturing apparatuur
Confidential May 10th, 2011

22. MEDIC
Implementation of the CCR
Central location near the line
Proces visualisation
Document pc
Machine control
Camera system
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23. MEDIC
Secondary Metrics
Line Output Efficiency
100%
95%
90%
85%
80%
LOE
75%
70%
65%
60%
PRE PILOT IMPLEMENTATIE / DOCUMENTATIE
55% CCR
CCR CCR CCR
50%
jan feb mrt apr mei jun jul aug sep okt nov dec
Maand
Waste
14%
12%
10%
8%
Waste
6%
4%
PRE PILOT IMPLEMENTATIE / DOCUMENTATIE
2% CCR
CCR CCR CCR
0%
jan feb mrt apr mei jun jul aug sep okt nov dec
Maand
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24. DMAIC
Roles and responsibilities
• Escalation model out of control
– On 1 A4
3 2 1
Confidential May 10th, 2011

25. DMAIC
Addition to the Central Control Room
Visualization out of controls
Last 24 hours
Real-time Visualization on critical product parameters
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26. DMAIC
Learning and future
Breakthrough- and Continuous Improvement
Complementary to Each Other … External CONQ from
decreased
(2008  2009)
• Machine OCAP  Line OCAP
• Continuous operator engagement
Prevented internal
• SMED
CONQ
decreased
Confidential May 10th, 2011
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27. How to make the difference in the future in
Western Europe UNIQUE GTDM CORE COMPETENCES
Level 6 - flexible lines (many product types)
- control 6 sigma (scada +MES)
- Central Control Room (lean)
Laser processing
Micro welding
Micro dosing & small parts handling
product Vision systems
development Light measurement
Glass processing
Glass-metal joining
Organic sources (OLED)
Close Information systems
cooperation Vacuum & Gas Technology
Mechatronics
a learning Process & Coatings
flexible Equipment Positioning
production development Turn-key equipment
Heat management
Confidential May 10th, 2011