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ROBOT WELDING SETUP

REDUCTION TRAINING

November 14, 2013

By Julian Kalac, P.Eng

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Problem Statement & Objective

Current setup time= 40min

Standard Time= 15min

Target setup Time < 5min

Helping Our Customers Be More Successful . . .

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Benefits of SMED

• Reduced setup time

• Higher efficiencies

• Increased capacity

• Reduced WIP’s

• Lower batch sizes

• Increased safety

• Increased flexibility

• Elimination of waiting

• Operators preference

• Stockless production

• Less Scrap & Rework

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SMED (Single Minute Exchange Die)

• Setup Time– Starts when last piece of previous job is complete;

ends when first good piece of next job is complete

• Internal set-up: While machine is shut-down– Strive to minimize this as process is not producing

parts

• External set-up: While machine is working– Prepare for set-up, get all tools/parts needed ready

and beside the press before starting set-up

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Seven rules for improving Setup

1. Setup improvement begins & ends with 6S.

2. Change Internal (on line) setup into External (off

line) setup then improve any remaining internal

changeover. Ask WHY again & again.

3. Find alternatives to bolts (they are too slow to get

on & off).

4. If you have to use your hands make sure your feet

stay put.

5. Don’t rely on special fine tuning skills.

6. Standardize all changeover operations.

7. Standards are standards / they are not flexible.

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Internal Vs. External (cont’d)

• Primary goal is to change all internal setups to external

ones

• Reduce length of internal setup if unable to convert to

external

• Reduce length of all external setups as well

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Simple Suggestions

• Analysis of setup procedures using videotapes

• Use more people where available

• Use offline time as maintenance time

• Practice makes perfect

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SMED Examples

• Split thread bolts

• Handles

• Toggle clamps

• U-shaped washers

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Example Tools (cont’d)

u-shaped washers Split thread bolts

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Example of SMED Tools

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Quick Connect Toggle Clamps

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The spring-loaded, one-

handed clamp with quick-

set, magnetic V-Pad.

Quick and easy to use!

Squeeze to open, set in

position and turn to

tighten.

MagSpring Clamps

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Sliding Channel Clamps

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Table Mount C-Clamps

Quick Connect Clamps

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Robot 9 Set-Up Reduction Project Action Items

1-5S work station (label tools, screws, nuts & fixtures)-->Brent Nov 14

2-Fabricate welding fixture for 6/22 parts, --Andrey Nov 14

3-Program needed changes --> Earl To be scheduled

4-Redo Setup video same part after 5S --Brent/Julian--( to be sched)

5-Program all parts to run on both sides—Earl 9/22 parts ?

6-Implement a setup/downtime tracking sheet –Julian Nov 14

7-Implement a suggestion log for operators—Julian Nov 14

8-Etch in GRIDS onto the welding fixture—Brent Nov 14

9-Post “To Do List” at Robot 9 cell—Julian Nov 14

10-Decide if Air Gun or Air Rachet is more feasible—Earl—Nov 20

11- See if Robot cn position for Ream from the front side—Earl—Nov 20

12-Anti Spatter tank Earl –Nov 15

13-Colour Code the fixtures as per the setup sheet –Brent Nov 15

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ROBOT 9 ZERO SETUP TIME

PROJECT

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Robot 9 Weld Cell Process FlowProcess/Material Flow

Step 1Parts From Brake Press

Step 2Tacking

Step 3Robot 9

Step 4Clean Part

Step 5Out to next operation

Move the welded

parts out ASAP

Screw weld blocks onto fixture 10-15min why?

WELD

FIXTURE

WHATS THE

PROBLEM?

SPEED OF

RACHET

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Screw length

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STANDARDIZE SCREWS

PROBLEM SOLUTION WING NUTS

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Robot 9 SMED SOP=ZERO SETUP TIME

SIDE A CHANGEOVERstep # Operation Est Time (min)

1 PREPARE NEXT WO MATERIAL 4

2 GET NEEDED FIXTURES/TOOLS/CLAMPS 3

3 UNLOAD LAST PARTS FROM SIDE 1 1

4 INSPECT AND TOUCH UP PARTS 2

5 TACK PARTS 2 (EXTERNAL SETUP)6 TAKE DOWN FIXTURE FROM SIDE 1 4 BEING DONE

7 LOAD PARTS ONTO SIDE 1 1 WHILE ROBOT rUNNING

8 START WELDING SIDE 1 0

TOTAL TIME FOR SETUP= 16

WELD CYCLE STARTED = 8 T SETUP TIME CLOCK STARTS

AFTER 8 MIN

SIDE B CHANGEOVEREXTERNAL SETUP

7 TAKE DOWN FIXTURE FROM SIDE 2 5 INCLUDED IN

8 LOAD PARTS ONTO SIDE21 1 WELD CYCLE (8MIN)

9 START WELDING SIDE 2 0

TOTAL SETUP TIME SIDE B= 6

TOTAL INTERNAL SETUP TIME= 0

TOTAL EXTERNAL SETUP TIME= 12

OLD SETUP TIME (MIN)= 38

DEC 4 SETUP (MIN) = 0

SETUP TIME IMPROVEMENT (MIN) = -38

WHILE THE ROBOT IS WELDING SIDE B, LOST TIME=0 MINGOAL IS TO CHANGE STATION A BEFORE ROBOT FINISHES WELDING SIDE B

DURING WELD CYCLE (8MIN) THE FOLLOWING WAS DONE

Robot 9 SetUp Time Savings (228/229 parts)

OLD SetUp Time for Robot 9 SetUp Time

(Min)

SetUp Time

(Hrs)

Number

SetUps/Shift

Total SetUp

Time/Shift

Total SetUp

Time/Day

SetUp

Time/Week

SetUp

Time/Year Machine Rate

Annual Lost

Productivity

38 0.63 2 1.27 2.53 12.67 595.33 $ 100.00 $ 59,533.33

DEC 4TH SetUp Time for Robot 9= ZERO SETUP TIME SetUp Time

(Min)

SetUp Time

(Hrs)

Number

SetUps/Shift

Total SetUp

Time/Shift

Total SetUp

Time/Day

SetUp

Time/Week

SetUp

Time/Year Machine Rate

Annual Lost

Productivity

5 0.08 2 0.17 0.33 1.67 78.33 $ 100.00 $ 7,833.33

Hrs Saved 517.00

$ 51,700.00 ANNUAL SAVINGS =

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