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Auto Soundproofer Entrusts Cybernet for Production Lines

UGN is an award-winning company that specializes in linings for automotive applications. From carpeting to dashboard insulation to seatback foam, UGN creates the molds, batting, and carpets that go into automobiles. Founded in 1986, UGN focuses on products that aid thermal and sound management and doing it in a sustainable and environmentally-friendly way. Some of their largest clients include Honda, Toyota, and Nissan, making them a juggernaut in the industry.

Challenge Icon Challenge

Manufacturing software can’t last forever: there’s always going to be a new feature, a fresh idea, or a new strategy to improve production. When it came time for UGN to do an overhaul of their software, they realized that their old computers just didn’t have the processing power or memory to handle the new program.

Any computer they deployed would primarily be used to help make sure that the proper parts were being given the proper labels at the end of the manufacturing line, ensuring that the right product not only went to the right shipment but that the product met UGN’s high standards.

The environment proved a challenge as well. The computers at the end of the production line were often near the dock and exposed to varying degrees of extreme heat, cold, moisture, and wind. Small particles like dust, fibers, and remnants from foam-cutting also float around the facility. The computers would also have to survive the fleece department, which is intentionally kept quite humid by water misters installed in the ceiling.

Solution Icon Solution

UGN has been using Cybernet computers in various forms for years — some of them had even lasted almost ten years, and were only being replaced as part of the hardware refresh and upgrade. The iOne H5 model, which hit the market in 2007, were still in limited operation in a few of the UGN production lines.

Since Cybernet was still on their radar and performing admirably despite years of wear and tear in unfriendly environments, they decided to move forward with the next generation of Cybernet’s enterprise grade all-in-one computers, the iOne H6 for their newly upgraded software.

The iOne H6’s came with the same 20” display, which made the screen clearly visible even installed inside a protective housing and behind glass. The sealed front bezel, IP64 ingress rating, and IPX1 back cover ensured that the dust and lint in the air wouldn’t be a problem and that the computers themselves were easier to clean. And, with a temperature tolerance of anywhere from 32°F (0°C) to 122 °F (50°C), the H6’s were able to perform all of the necessary duties no matter the temperature.

Results Icon Results

The initial deployment was a success, with iOne H6’s going on to be installed in large swaths in their facility. The new devices fit perfectly in the protective cabinets of the old devices, largely due to Cybernet’s policy of maintaining similar computer form-factors for continuity purposes. The universal VESA mount hardly changes, either, which aided the easy transition.

UGN found that the all-in-one nature of the iOne H6s made cable management a non-issue, and they enjoyed the built-in wireless connectivity that didn’t require an additional external dongle like most desktop computers. The iOne H6s connected with their networks easily and were able to communicate effectively with their PLC for verifying parts and printing it the right labels.

Since the initial deployment of Cybernet units, UGN has begun to upgrade their factory floor to the iOne C22. The newer Cybernet units can be expanded to up to 16MB of RAM, which became a necessity after upgrading their software a few years back. Sticking with Cybernet was an easy choice considering all of the iOne H6 units they had initially purchased were still running strong.

There's a lot of lint and dust, and the fleece department is very humid. They actually have misters in the ceiling that sprinkle down. I also have these computers out close to where they're shipping, out by the dock doors, so it can be really hot, damp, or cold, even. It can get over 100 degrees, especially in the summertime. They're rugged.

- Eva Leach,