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Home arrow Case Studies arrow Factory automation: Siemens equips Kia Motors first European factory
Factory automation: Siemens equips Kia Motors first European factory Print E-mail
Written by Stephen   
Tuesday, 12 February 2008
KIA goes TIA

Following several locations in Asia, Siemens has now also automated the essential areas of Kia Motors’ first European factory in Slovakia. With Totally Integrated Automation, the seed has been sown and the production of the Cee’d equipped perfectly for the ambitious goals of the Korean company.

The Hyundai-Kia Automotive Group set themselves the ambitious goal of becoming the world’s number five automobile make by 2010 years ago. And the Koreans are very close to achieving this goal soon – with sales of more than 3.7 million automobiles they are presently number 6 in the world ranking list according to their own survey. European buyers are intended to bring further growth in future parallel to the Asian and North American markets. The pearhead in the fiercely contested C-segment is the Cee’d which certainly has what it takes in terms of styling, performance, quality and handling.

KIA motorsKia Motors Slovakia (KMS) has invested approximately one billion euros to create state of the art conditions for the production of up to 300,000 automobiles in the final assembly: paint shop, assembly shop and engine shop are equipped almost entirely and consistently with electrical, automation and drive technology made by Siemens, as is the production of modules at the company’s own supplier Mobis as well as parts of the press shop.

Siemens products in (almost) all shops For the Koreans, the first and most important step in the automation is the choice of the make of controller from which all other components are derived. The good experience (and contacts) from previous projects were again instrumental in the decision in favor of Simatic and ultimately for the many other Siemens components. From circuit breakers and power supplies via controllers, industrial PCs, converters, motors and large drives to HMI and safety technology, the automobile manufacturer has specified Siemens for all OEMs in the paint- assembly and engine shop.

KIA Motors- Siemens has automated the paint shop, assembly shop, engine shop and other sections of the new Kia factoryThe assembly shop and paint shop alone contain more than 200 operating panels consisting of one Simatic TP270 touch panel and one PP17 pushbutton panel each for operating and monitoring the conveyor equipment. Kia has chosen these in preference to the standard devices of the system supplier. The paint shop equipment was pre-wired at Siemens and delivered ready to install in switch cabinets. The user interface of the touch panel is designed for online switching between English and Slovakian.

Premiere for Profisafe

Because much stricter safety regulations apply in Europe than in Asia, Kia has chosen a safety technology based consistently on Profibus and Profisafe for the first time. At the heart of this are failsafe designed and operating Simatic S7-400F and S7- 300F controllers which handle standard and failsafe communication with the distributed Simatic ET200S (Profisafe) I/O modules via conventional Profibus. Mixed use of standard and failsafe input/output modules in the field enables simple, lowcost installations which are also much more flexible than conventional, permanently wired systems.

Totally Integrated Automation from Siemens forms the backbone of several key areas of the new factoryThey also offer very convenient diagnostics. KMS has again used the diagnostic repeaters from Siemens proven in other factories with which any malfunctions can be localized very quickly and precisely from a central station. This helps to minimize downtimes and keep the availability and productivity at a very high level.

Maximum transparency

To avoid interfaces and the associated breaks in the automation, the automobile manufacturer has also specified a Siemens solution for the control and visualization of the painting robots. Together with the robot manufacturer, both a Simatic control solution and a SCADA system was developed under Simatic WinCC which is linked to the central MES system in the factory and continuously monitors, records, archives and reports the specified process parameters (viscosities, temperatures, humidity values, etc.). Standard drive solution for the conveyor technology and the ventilation system in the paint shop are Micromaster 440 converters and motors of the 1LA or 1LG series. Siemens’ extensive equipment portfolio is rounded off by 1PQ large drives on various large presses. And a free training for the user’s operating personnel so that the first production stage could be started on schedule in December 2006.

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