Esys Capabilities 2009 English

Esys at a glance

Incorporated in 1999

75 Engineers on Staff

Open Book Management / PSP

2008 Revenue Sales of $18 Million

45,000 Sq Ft Facility

Markets We Serve Our Capabilities

• Automotive• Logistics• Defense & Aerospace• Government Agencies• Low Volume Manufacturing

• Engineering Services• Integration & Custom Manufacturing• Robotic Sealing & Coating Applications• Material Handling Solutions• Custom Machines and Test Systems• Machine rework / retrofit / upgrade / relocate• Design and build of PLC based control systems• SCADA Systems• Manufacturing Execution Systems (MES)• Tire & Wheel Assembly Solutions

Engineering Services

Mechanical Engineering•Pro/Engineer, •Unigraphics•AutoCAD

Electrical Engineering•AutoCAD •ePlan

Controls & Software Engineering •Allen-Bradley•Siemens•Mitsubishi etc…

Additional Advantages

• 2D to 3D CAD Conversion

• Technical Data Package (TDP) Creation

• Configuration Management

• Manufacturability Studies

• Requirements & Specification Definition

• Conceptual & Feasibility Studies

• Design for Manufacturing

• Mechanical Design and Analysis

• Mechanical 3D Modeling & Detailing

• Electrical Hardware & Software Design

• System Integration

• Simulation and Animation

Integration & Custom Manufacturing

Our Capabilities Include:• Supplier maintained inventories• Scalable workforce• Light machining• Dry Ice blasting & machine cleaning• Piping and Wiring• Pneumatics & Hydraulics assembly• Material management and kitting• Extensive Subcontract Network

•Precision Machining•Proto-typing•Painting & Powder Coating

Applications Include:• Integration

•Material Handling Equipment•Water Spray Booths•Robotic Cells•Machine Repair, Retrofit, Upgrade

• Custom Manufacturing•Electrical Control Panels •Enclosed Industrial PCs •Operator Interfaces•Pick-bins•Custom machinery

Additional Advantages• 25,000 Square feet• 10 Ton overhead crane• Ground level bay shipping• Dock level bay shipping• 10K AMP power• Clean power• 62 cfm distributed air drops• Real-time webcam monitoring• R&D area

Design & Build of PLC Based Control Systems

Control Upgrades

• Replace proprietary controls• Common off the shelf components

Our Capabilities Include:

• Allen-Bradley Logix Platform• Factory Talk• Siemens S7• Siemens WinCC• EPLAN• VFD & Servo Systems• Specification & Standards Development• Complete Panel Build

Applications Include:

• Automotive Body Assembly• Paint Systems• Automotive General Assembly• Conveyors - Skid, Skillet, P&F, AGV etc.• Part Transfer Systems• Stamping & Presses• Waste Water, Water Treatment, RO

Vision Systems

Our Capabilities Include:

• Interface to PLC & Tooling• Intuitive Operator Interfaces• One Touch Teaching Software• Image Logging and Reporting• Remote IT Support• On-site Support• Inexpensive Hardware Solutions• Training and System Documentation

Applications Include:

• Part Identification• Mistake Proofing• Defect Detection• 2D & 3D Barcode• Assembly Verification• Tire Tread Vision• Wheel Type Detection• Tire & Wheel Match Mark• Stem Detection / Orientation• Robot Path Correction

Robotic Sealing & Coating

Our Capabilities Include:

• Process and Feasibility Studies• Simulation – Reach & Cycle time• Critical Dimension to Body Zero• Mechanical Design• Bulk Material Delivery System Design• Controls & Safety Design• Build and Detailed Commissioning• Complete Installation Services

Applications Include:

• PVC Anti-Chip – Stone Guard• Cosmetic Sealer• Roof Ditch Sealer• Seam Sealer• Liquid Applied Sound Deadener (LASD)

Additional Advantages

• Multiple Material Applications• 2K Applications• Masking Applications• Temperature Control• Bulk Material Pumps• Fixed Vision Systems• EOAT Vision Systems• 7th Axis & Pedestal Robots• Cell Layout• Site Surveys & Laser Alignment• Fluid Calculations• Payload & Inertia Calculations• Safe Distance Calculations• Thorough System Documentation• Off-site & On-site Training

Custom Machines & Test Systems

Our Capabilities Include:• Electrical Engineering• Mechanical Engineering• 3D Modeling• Software Development• UHF & LF Experience • Extensive Testing Tools• Integration and Validation Space• Supplier Network

•Proto-typing•Precision Machining•FEA, Simulation

Applications Include:• Electrical Test Systems• Precision Cutting• Material Dispense and Cutting• Measurement Sensing• Low Frequency Radio Applications• Ultra-High Frequency Radio Applications• Specialized Material Handling & Sorting• Robotic Manipulation• Wireless Devices• Wireless Connectivity to Infrastructure• Vision Systems

Machine Rework / Retrofit / Upgrade / Relocate

Our Capabilities Include:• Electrical Hardware Design• PLC & HMI Design• Motion Control• Mechanical Teardown and Assembly• Dry Ice Blasting & Machine Cleaning• Piping and Wiring• Pneumatics & Hydraulics Assembly• Painting & Powder Coating• Full Debug and On-site Startup• Installation Services and Site Management• Training and New System Documentation

Applications Include:• Control Systems Upgrades• Servo Upgrades• VFD Upgrades• Robotic Sealing• Robotic Welding• Roller & Belt Conveyors• Various Material Handling• Tire & Wheel Equipment• Printing Presses• Paper Converting

Material Handling Solutions

Our Capabilities Include:

• System Layouts• 3D Design• Process Studies and Simulation• Custom Fixture / Carrier Design• Part Tracking• Full Debug and On-site Startup• Installation Services and Site Management• Training and System Documentation• FKI Logistex Integrator

Applications Include:

• Chain Driven Live Roller (CDLR)• Line Shaft Conveyors• Belt Conveyors• Stackers & De stackers• Palletized Systems• Part Orientation Systems• Lift Assists• Robotic Applications

Tire & Wheel Assembly Solutions

Our Capabilities Include:• Process and Feasibility Studies• Simulation & Cycle time• System Layouts• Mechanical Design• Controls & Safety Design• Build and Detailed Commissioning• Complete Installation Services• On-site Support• Extensive Training and Documentation

Applications Include:• Complete Roller & Belt Conveyor Systems • Scheduling, Tracking, and Data Delivery • Wheel Load Process • Wheel & Tire Vision Systems• Robotic or Manual Stemming operations • Tire Load Process • Lift Assists• Material Racks• Marquee & Operator Interfaces • TPM Sensor Verification • Assembly Unload & Delivery • Product Traceability

Esys Tire & Wheel Assembly Solutions can be found in more than 60 tire and wheel assembly plants world wide.

Our Company Our Capabilities Markets We Serve News

Tire & Wheel Scheduling, Tracking & Data Delivery

Tire & Wheel Tracker System Highlights:

• Specifically designed to handle the data needs of a Tire and Wheel Assembly Process. • Large installation base and proven reliability • Single point of control and part information for a distributed system. • Not a FIFO but rather a "build manifest.“ - localizes sequence issues• PLC based (PC only as an HMI), this translates into extreme reliability • Capable of delivering data to equipment in less than 125m seconds• Not dependent on sequential processes (handles parallel lanes)• “Buffers" itself from the upper level broadcast system, up to 2-4 hours. • Allows for a single point to insert or remove assemblies• Editable "Dictionary" that allows users to enter critical production data

Our Company Our Capabilities Markets We Serve News

Contact Us File Exchange Esys Login

Dispense & Cut System for 3M Adhesive Wheel Weight Product patent pending

The Esys Dispense and Cut System (DCS) is a machine designed for dispensing and cutting 3M™ weight coil stock for use in balancing of automotive wheels. The 3M™ Wheel Weight

Technology along with Esys’ DCS eliminates the use of lead weights, reduces inventory of individual stick-on or clip-on weights, eradicates waste, and increases correction of imbalance

wheel assemblies by dispensing precise weights on demand.

Photos and logos used with permission from 3M

• High Torque Stepper Drive provides high level accuracy within +/- 0.5 grams (.0176 oz)

• Intuitive remote operator interface• Capable of dispensing multiple weight profiles • Batch Cut Feature by size and quantity• Product select by linear density• Quick release blade for easy changing• Provides center mark in weights• Material detection sensors for end

of material and splice detection• Easily integrates with balancer equipment• Built in safety features

Highlights: Options:

• Mount for boxed weight material• Automatic Unwind System for feeding 250lb spools• Diverter for Upper/Lower/Scrap Weights• Automated disposal system for liner• Pick-To-Light error proofing system

Support:

• Professional Service / Maintenance Manuals• On-Site Training• 24 Hour Emergency Support Hotline – Esys “Hot-Seat”

Support Staff• 1-Year Standard Warranty

3M Product Information

Tire Pressure Monitoring System (TPMS) Solutions

Applications Include:

• Data Marriage Systems• Verification Systems• Handheld Tools

Our Capabilities Include:

• Operates with nearly all sensors on the market• Siemens• TRW• Lear• Pacific

• Redundant RF receivers in every antenna. • Broadband Technology to handle multiple frequencies • Digital receiver "tunes" itself• Advanced software algorithms to distinguish bad signals • Variable LF module with power output readout• Designed to integrate into existing PLC / PC control systems• A monitored cam break-away stand - vertical or horizontal mount

• Schrader• Hyundai • Autonet

With Manufacturing Execution Systems (MES) options starting at under $30,000.00, Esys offers the least expensive MES system on the market.

On the plant floor, operators and tooling have the biggest impact on cost and quality. Esys provides the first and only manufacturing execution (MES) system to emphasize on the operator and tooling.

Esys MES solutions are built by manufacturing integration engineers, not IT software people. Our engineers spend more time on concrete than carpet, creating real world solutions for manufacturing excellence.

Our Capabilities Include:

• Interfaces to ERP/MRP/WMS• Interfaces to PLC’s, Tools & Testers• Intuitive Operator Interfaces• On-site & Remote Support• Inexpensive Hardware Solutions• Training and System Documentation

Applications Include:

• Genealogy & Traceability• Quality Systems, SPC• Paperless Work Orders / Travelers• Electronic Work Instructions• Pick to light, Put to light• Material Visibility

MES Benefits:

• Increased Productivity• Reduce waste• Increase quality• Reduced inventory• Better metric information

Esys MES Software Solutions

Genealogy & TraceabilityLess than accurate traceability and genealogy data can cause untold lost profits.

Our manufacturing knowledge allows us to collect data with greater integrity than ourcompetitors, with concise reporting customized to your specific needs.

Esys MES Software Solutions

Applications Include:

• Genealogy & Traceability• Quality Systems, SPC• Paperless Work Orders / Travelers• Electronic Work Instructions• Pick to light, Put to light• Material Visibility

Quality Systems, SPC• Enforces product tolerance checks using control charts• Early detection of variances that would adversely affect quality• Correct defects before subsequent processes begin• Some of our system benefits include:

• X-R quality control charts for SPC• Parts / Processes easily added, modified using color coded tree views• Data collection accomplished via machine interface or operator entry

Esys MES Software Solutions

Applications Include:

• Genealogy & Traceability• Quality Systems, SPC• Paperless Work Orders / Travelers• Electronic Work Instructions• Pick to light, Put to light• Material Visibility

Electronic Work InstructionsElectronic work instructions lower training cost and provide consistent quality.• Designed for high option content workstations• Allow operators to move seamlessly from workstation to workstation• Easily configurable for process changes,• Capable of displaying graphical images

Esys MES Software Solutions

Applications Include:

• Genealogy & Traceability• Quality Systems, SPC• Paperless Work Orders / Travelers• Electronic Work Instructions• Pick to light, Put to light• Material Visibility

Pick to Light, Put to LightA standard for some of the world’s largest manufacturers, Esys is one of the only providers of non-contact “pick to light” systems. Our fully implemented systems are typically 25% less expensive than our competition’s.

Esys MES Software Solutions

Right Part• Easily identifies part to pick• Notifies pass/fail operations• Ensures correct tasks are performed

Right Place• Flexible station locations• Mobile job stations available• Individual indicators per part/station

Right Time• Operation downloads in real-time• Real-time result logging• Informs operator in real-time

Applications Include:

• Genealogy & Traceability• Quality Systems, SPC• Paperless Work Orders / Travelers• Electronic Work Instructions• Pick to light, Put to light• Material Visibility

0%

10%

20%

30%

40%

50%

60%

70%

80%

Below ExpectationsMeets ExpectationsExceeds Expectations

[ ISO 9001:2000 Certified[ 99.2% Overall Customer Satisfaction[ Data compiled from over 60 individuals

All efforts are to be focused on meeting the needs of the customer.We will provide our customers with a level of service, support,

and competency that is the benchmark of the industry.

OUR CORE BELIEF