Data collects a system to receive solder unit to produce efficiency to rise greatly

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  • source:AVELLINO CNC Machining
Company of Northern Stamping of car component supplier, be located in Ohio, mix with punch solder the robot has production. This company and labour union talk things over, established standard of an obtain employment: The yield that the jockey in the factory must produce for its personally and quality are responsible. Of course, the administrative layer of the company also can give get one's own back accordingly, what acceptance safeguards manufacturing facilities with all one's strength is normal move, made maintenance is in first-rate performance level. The robot that article author saw this company be located in area of Ohio Valley View solders workshop, cover an area of an area to make an appointment with 141000 square in all foot. Over, technician people serious ground monitoring all soldering that wait with automation equipment, clamping apparatus, realize its optimum behavior in order to ensure. Administrative layer still established the manufacturing drive mechanism that is aimed at an individual, encourage employee to achieve the manufacturing efficiency that exceeds official level. In producing incentive mechanism, each class asks duty make have distinguishing feature extremely. It makes this factory (one of main suppliers of general motors) absolved the indirect quality monitoring of 2/3. "We solder from our robot manufacturing data is collected directly in unit PLC, " operation vice-president Scott Sheffield says: "We were rolled out 2003 dog the system stops engine problem with solving, began 2007 again comprehensive and compositive this kind of system. Before this, we are honest the work efficiency that tweak of it doesn't matter will come to control every employee on every order in the round. " the trailer couple business of general motors company and from the business that takes over over there manufacturer of other link up with, make the business of Northern Stamping company swift and violent growth. The company has 70 to solder robot, move with the means of odd, double, quaternion. Every lot that assembles unit to be able to undertake independence but retroactive punch flow. Core competition ability: The robot solders memory of president Matthew Friedman says: Going up century 90 time metaphase, northern Stamping company first sortie robot solders, the GMT800 skin that they just received pay of general motors company in those days blocks the manufacturing project of the car. The company basically is in charge of the beam in this project and the punch that twist lever soldering, set Valley View welder plant newly 1997 even for this company. To soldering package has the process of punch, it is to those who undertake is in in the company's original workshop that is located in Cuyahoga Heights (cover an area of 1161000 square foot) . This punch shop is small all the time in local punch industry have great reputation. The father of Friedman and his copartner bought it 1989. The business of GMT800 Pi Ka increases ceaselessly, more and more fire, drove Northern Stamping company to enlarged its to build 1998 solder workshop. Company mushroom 10 robots solder unit, with will assemble engine bracket and beam to twist lever, still added a pair of robot solder to receive unit again 2001. "Our growth ground is very rapid and remarkable, " Friedman says: "But 2004, as GMT900 lorry platform roll out, we got not little impact. GMT800 skin blocks a project (inside have a new-style and pensile system) , make we reduced 65 ％ in the business on GMT900 lorry platform, because of the great majority component that we produce at that time, it is to be this skin lorry only and of the design. " he says: "But because of our fill this one blank, general motors company rewarded us to restrain 12 million dollar on trailer couple business 2004. To May 2005, we already became the main supplier of the trailer couple of card of skin of general motors company and SUV car. " the trailer couple business of general motors company and from the business that takes over over there manufacturer of other link up with, make the company was added newly again additional 5 robots solder unit, the robot that still increased a 4 stage an organic whole 2009 is unit (MOTOMAN company makes) . This robot of 4 an organic whole is unit, use at soldering originally the bridge beam of bold carriage, already was converted now the new generation that accepts general motors firm at solder is heavy-duty link up with. Still be in 2009, the company added his newly still resistance welding of the first robot is unit. Appear always, this solders now in the factory, share 60 70 robots, hours to be versed in, include division of 3 welder Cheng, 3 solder mechanic falls two classes. Nextpage improves productivity and quality desperately slowly slow and steady, keep consistent from beginning to end, year answer style of work of a year of ground, make the company decreased to solder greatly periodic, improved quality, optimized solder to receive unit normal run time. During this, the company returns the body that turns the task that is in charge of to produce quality to operator to go up. Of course, the company also was offerred during groom necessarily, in order to make the success that this responsibility transforms. Sheffield says: Now, the man-machine interface that the company can carry every unit (HMI) , dog each solder unit each operation detail, include production and machine down time, clear up the generation reason of all and brief stoppage. "Work even if maintain the normal motion of the robot and solder of operator to receive unit normal production, " Sheffield says: "Pervade the data of whole company network is collected, mix all all together binding. Administrator can see direct seeding of manufacturing current situation in real time, see what every unit in the factory produced after all, and the goal of production that who is in charge of realizing this solder to receive unit is after all inside specific time. In addition, the every time that we have is assembled on, have specific but impress of punch of date from sex, its action and sign one's name are same. " the responsibility that every employee in the workshop needs to load, measure standard fractionize to make by a few when the company makes. After using this kind of system, the solder of whole factory the scale that accepts unit machine down time to take total machine down time 28 from 2004.

6 ％ dropped 16 2011.

2 ％ . The fractionize that collects data according to be opposite, dog and record investigation, company discovery stops engine is main the following reasons bring about: The part that ◆ exceeds tolerancepublic errand limit returns solder to receive unit; ◆ to set according to union labor contract, the contract both sides that brings about because of individual reason all agrees stop machine; The; ◆ that ◆ and operator concern and safeguard what concerned; ◆ and management concern to groom, the; ◆ such as regular meeting awaits component to reach this worker worker. For the part that produces to certain big batch, productivity is very important, be with periodic time reduce those who will measure. "Our data collects the job, still operator individual asks duty make, great to the meaning of manufacturing it may be said of these component, " Sheffield says: "We also use these data to arouse those who produce flow to improve. " Northern Stamping company can dog every solder each unit detail, the man-machine interface that carries every unit (the leftmost in the graph is namely) , win production, machine down time and the account of any brief stoppage. Begin to time begin to solder in every when data is being collected on unit, login on the HMI that needs every operator to receive unit in its solder in the morning everyday. In those days, they can see one welcomes screen, ask they agree with the following allegation: I agree, I already was accepted groom, already was read and will abide by the program of all standard work that concerns with this job unit, operation to check instruction and working security to ask. Once he was clicked " Yes " pushbutton, began to time. "Begin to run first time to solder in product line when assembling pressure to check, they have time of at least 40 minutes, " plant manager Jessie Meet says: "Every check check the number of (the likelihood amounts to 14) the metropolis is automatic regard the operation as not of up to specification, till this operator the examination ends to move its into " green " signal. Next, also be only after this, operator just can solder that unit catenary flows into whole production in Cheng. " receive unit as solder move, administrator can visit the data that collects from the workshop arbitrarily, close and censorial these data. "These data that collect quickly, include to solder size of the date, operator, component amount that processing, lot, how many component already was machined, how many still is waiting to be machined. " Meet says: "We can see how many assembly parts has been hit by operator label steel seal, how many assembly parts was rejected by its, the reason wheres. The entry that we can see operator and record a time, reach its the total time inside the system, the standard photograph that agrees to abide by with its is compared, how much is the practical productivity with this hourly operator after all. " " the key is the idling time that still can trace product line, " Meet says: "Can this help us whether to get between hair of as soon as possible any harm? Once appear ' Yes ' reply, will feedback to have probe there administrative layer instantly. " the system of job responsibility that reduces in-house reject and operator of rate of do poorly done work over again and but date from sex, still can reduce in-house percent defective and rate of do poorly done work over again. Meet emphasizes: "There is the ID number of operator on each component, so any component are mixed weldment won't by optional ground, without ask duty the ground discards as useless. Before, raw material treatment is the process of finished product, very difficult (although not be impossible) be dogged and control, so we run after all with respect to very difficult certain material where went. " after using data to collect a system, arrived 2006 during 2011, the flotsam of Northern Stamping factory is led from 1.

2 ％ drop to 0.

5 ％ , rate of do poorly done work over again also falls from 6 ％ 2 ％ . Dog reject and reason of do poorly done work over again, make Sheffield and its group knew what component receives unit to produce waste material the most easily with solder, facilitate they adopt measure in time to solve this problem. The system still designed a group to provide data for the interior of the company, use at the design of fixture and framework, still affected the design of punch mould and framework flow even in certain moment. 2007, northern Stamping company no longer outside bag, begin oneself to undertake the design of fixture and framework. Now, this investment that has in personnel and equipment already won bonus of a huge sum. Meet citing says: "We took over a business that hang catenary from a terribly defeated supplier place recently. When we throw production, the sensor of fixture workshop almost two days of one problem. But below the help that collects a system in data, our clamping apparatus branch always can find out problem place quickly, install sensor afresh, solder to this the property that how they protect better in the environment undertakes adjustment. But if flow of this clamping apparatus is outside the bag goes out, probable a few days of ability solve a problem, affect our manufacturing schedule. " when loginning on the HMI that every operator receives unit in its solder in the morning everyday, can see one welcomes screen, ask they agree with the following allegation: I admit, I already was accepted groom, already was read and will abide by the program of all standard work that concerns with this unit, operation to check instruction and working security to ask. Matthew Friedman memory says: Going up century 90 time metaphase, northern Stamping company first sortie robot solders, the GMT800 skin that they just received pay of general motors company in those days blocks the manufacturing project of the car. The company basically is in charge of the beam in this project and the punch that twist lever soldering, set Valley View welder plant newly 1997 even for this company. "Still have another case, " Meet continues to say: "Soldering once when the car builds stamping workpiece, production tracks and stop machine signal to warn administrator suddenly: Solder speed is putting delay, the lowermost cost that productivity allows than the regulation is low still. This caused administrative layer opposite to produce the microscope of the process instantly. Because punch process solders mediumly,they discover later is span is too wide (this is wear away by punch mould and bring about) . Although this approves component to still be inside deviation limit, punch workshop and tool workshop still solved this to approve a mould. We rose to solder finally speed, return the level with acceptable regulation afresh. " what with grooming fill skill breach still needs to emphasize finally is, northern Stamping company runs a group, track from production and machine down time on the discovery after acquisition data analyses: Between the technical level of its operator and responsibility heart, still put in difference. Want to make up for this difference, need undertakes grooming to them. Administrative layer can use existing hard data, spend what make individuation personally to groom for them, in order to solve the specific problem of everybody. "Lift changing welding torch nozzle and the example that welding torch appears in head flow, " Sheffield says: "A few years ago, we notice change the nozzle of small effect and welding torch head can bring about overmuch machine down time, operator often is to hold solder blowtorch, book them the position to carry away from robot arm endmost. At this moment operator needs to transfer into concerned readjust solders the technology of flow, this regular meeting is brought about stop machine. " " now, we were offerred for operator with change of the process that nozzle and welding torch head concern and technology groom regularly, if nozzle and welding torch head stemmed,still taught them this how to handle, " Sheffield continues to explain: "Operator signs up for to us no longer on with equipment or safeguard those who concern stop machine ground. Contrarily, present stopping engine problem is different operator level differs the problem that cause. " the individual asks duty make, will have long-term positive effect in technological process of each stage production. CNC Milling