Setup Reduction training using SMED (Single Minute Exchange Die) and modular welding fixtures

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ROBOT WELDING SETUP TIME REDUCTION
TRAINING
November 14, 2013
By Julian Kalac, P.Eng

2. 2
Problem Statement & Objective
Current setup time= 40min
Standard Time= 15min
Target setup Time < 5min

3. 4
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 Flow
Process/Material Flow
Step 1
Parts From Brake Press
Step 2
Tacking
Step 3
Robot 9
Step 4
Clean Part
Step 5
Out to next operation
Move the welded
parts out ASAP

20. Screw weld blocks onto fixture 10-15min why?
WELD
FIXTURE
WHATS THE
PROBLEM?

21. 22
Screw length
HERE IS THE PROBLEM

22. HERE IS THE PROBLEM

23. 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 Comments
1 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
16
Separate External from Internal Set-Up action items (1st
pass)
Brent/Julian 18-Nov Completed
SMED 1st Rev = Internal SetUp 38min
> 18min
17
Develop a DRAFT Set-UP SOP Brent/Julian 26-Nov Open
40% completed. Need to validate new
setup time
18
19
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
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-Clamps
www.stronghandtools.com/build
pro
3/8”
OPTIONS

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1/12/2016
Department Reference #
Confirmed By Date Chapter Rev. PageIssuer
Production 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
Stands
Blocks
Riveting Anvils
Backing Blocks

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Ownership and pride

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STANDARD OPERATING PROCEDURE

36. Robot 9 SMED SOP=ZERO SETUP TIME
SIDE A CHANGEOVER
step # 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 CHANGEOVER
EXTERNAL 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 MIN
GOAL IS TO CHANGE STATION A BEFORE ROBOT FINISHES WELDING SIDE B
DURING WELD CYCLE (8MIN) THE FOLLOWING WAS DONE

37. SET-UP PROCESS STEPS ORIGINAL SETUP
TIME Min
NEW SETUP
TIME Min
Set-up
FIND 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 1
TOTAL SET-UP TIME 29.1 4
ROBOT 9 SMED
25 MIN Reduction

38. 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
$ 51,700.00ANNUAL SAVINGS =