lean setup reduction (smed) training for welding by julian kalac

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ROBOT WELDING SETUP TIME 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

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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.

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?

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Screw length

HERE IS THE PROBLEM

HERE IS THE PROBLEM

Robot 9 SetUp Time Reduction

Current setup time= 40min

Standard Time= 15min

Target setup Time < 5min LAST UPDATED

Item # Action Item Who Due Date Status Comments1 5S work station (label tools, screws, nuts & fixtures) Brent 14-Nov Completed

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

3 Program needed changes for new fixture Earl 21-Nov Open Critical for next step

4 Redo Setup video for BLUE GROUP (228/229 PARTS) Julian/Wayne/Carl 25-Nov Open Will have to do video with

5 Program all parts to run on both sides 9/22 parts ? Earl 30-Jan-14 Open

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

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

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

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

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

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

12 Anti Spatter tank Earl Earl 21-Nov Open New hose ordered

13 Colour Code the fixtures as per the setup sheet Brent 19-Nov Overdue 40% completed

14 Next Job Board Earl 26-Nov Open

15 Complete SMED training Julian 15-Nov Completed

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Separate External from Internal Set-Up action items (1st

pass)Brent/Julian 18-Nov Completed

SMED 1st Rev = Internal SetUp 38min-

> 18min

17Develop a DRAFT Set-UP SOP Brent/Julian 26-Nov Open

40% completed. Need to validate new

setup time

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November 22, 2013

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STANDARDIZE SCREWS

PROBLEM SOLUTION WING NUTS

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OPTIONS

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The spring-

loaded, one-

handed

clamp with

quick-set,

magnetic V-

Pad. Quick

and easy to

MagSpring Clamps

OPTIONS

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Sliding Channel Clamps

OPTIONS

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Hook

Clamp

s

OPTIONS

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Table Mount C-Clamps

OPTIONS

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Table Mount C-Clampswww.stronghandtools.com/build

pro3/8”

OPTIONS

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1/12/2016

Department Reference #

Confirmed By Date Chapter Rev. PageIssuerProduction manager

Rivet Cell 7.2- Shadow Boards

111May 11, 2006Scheduler

Cleaning Station

Rags

Shovel

Straw Broom

Cleaner

Push Broom

Colour coded cart used for storing riveting

anvils, blocks for the fixture, and stands

StandsBlocks

Riveting Anvils

Backing Blocks

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Ownership and pride

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STANDARD OPERATING PROCEDURE

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

SET-UP PROCESS STEPS ORIGINAL SETUP

TIME Min

NEW SETUP

TIME Min

Set-upFIND TOOLS 7.5 1 - Clamp Adjustment 1 0 - Clamps 2.1 0 - Wrenching 2.3 0 - Finite Reaming (1 time) 2 0 - Spacers 1 0 - Find Jigs 5 1 - Tack 4 pcs. 1.2 1

Material Preperation 7 1TOTAL SET-UP TIME 29.1 4

ROBOT 9 SMED

25 MIN Reduction

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 =