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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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