fast & easy machine setup project ( simply exchange of fİxture-sef ) &

FAST & EASY MACHINE SETUP PROJECT (SIMPLY EXCHANGE OF FİXTURE-SEF ) &

PILOT APPLICATION OF 4 AX MILLING MACHINE

Mümtaz ERDEM

6 Sigma

PROJECT SUMMARY

Project Y

ProjectDescription

ProjectObjectives/Goals

Customer/GEBenefits

Financial Benefits

Y Owner

MBB/BB

- PRODUCTION

SEF-Simply Exchange of Fixture and Pilot Application on 4 Axis Machine

Production Flexibility and Decrease Setup Time

•Reduced cycle time/improve capacity

6 Sigma

MMEASURE ANALYZE IMPROVE CONTROL

Project Title: Create an order to get tool, fixture, gage, and cnc program in digitam system

Status as of: Measure-Analyze Expected Completion Date:

Project Leader:

Project Y: PRODUCTIVITY

Y Owner:

Financial Benefits:

Team Members

Status

• Accomplishments: Data gathering, fixture and Machine

• Tools applied:• Significant findings:

Six Sigma Project Status

Name Function1-2-3-4-5-6-7-8-

Project ID#: -

BLACK BELTBLACK BELTSUPR.TOOLGREENBELTGREENBELT SUPERVISOR .SUPERVISORTOOL STOCKKEEPER

Project Statement & Benefits

• Scope:

• Goals & Objectives: Flexibility on production Decrease Setup Times

• Benefits: Reduced cycle time / Improve capacity

Next Steps

• Next steps:

• Additional tool to be applied: Design system &• Help needed: Yes

CTQ’s - Defect - Target

CTQ

Defect

Target

HIGH SET-UP TIME, NONFLEXIBLE SETUP

25% DECREASE OF S/U TIME & MORE FLEXIBILITY

STANDARDISATION

6 Sigma

4 AXIS / 36" PART NO OP. NO SET-UP RUN TIME N FIX NO FİXTURE GEO.FIX.DIA. FIX DIM(aXb) ALT.MACHMOUNT RING 1364M37G02 65 - 70 1,8 33.21 1 M91554 D 41"x 2.25

1364M37G02T 196 1 2MID GUTTER 1807M62P01 10 1,3 1,91 2 TEI 2764 D 24" X 2.5" MCB1210/MC98FORWARD RING1964M52P05 130 1 1,39 3 M93015 D 38" X 1.5" exp.LOWER BEAM 9348M61P01 3 0 2,35 4 TEI 1964 P 22"x7.5"x1"

115 2 2,03ACT.RING 9539M39G04 150 1,5 10,15 5 M91644 D 44" x 4

170 0,5 2,03 6 M91645 D 44 x 3"#7 BRG. HOUSINGL14405P02 70 1,5 3,2 7 M91057 D 28"X7" MCB1210/MC98TORK SHAFT L44815G01 105 0,5 3,8 8 M92420 P 41 "x 10" x1.5 "#4 BRG. HOUSING9646M10P03 60 0,3 3,3 9 M91102 D 26"X8" MCB1210/MC98

TABLE-1 MACHINE-FİXTURE & OPERATION DATAS

6 Sigma

01000020000300004000050000600007000080000

OPTIMES/U TIME

6 Sigma

0

5

10

15

20

25

30

35

M37 M52 M61 M39 L44815

OPS/U

OPERATION & S/U TIME RELATIONSHIP 6 Sigma

High S/UHours

METHODSEQUIPMENT

TRAINING

SHIFT

FLEXIBLE CHANGING

FIXTURE

FASTENİNG MAT’L

CARELESSNESS

CAUSE AND EFFECT

OPERATOR

CHIP CLEAN

STANDARDIZATION

6 Sigma

GENERAL VIEW OF THE 4 AX MILLING MACHINE

6 Sigma

b

•Capability of Holding up to 25” tools •Rotating Table & Machine Course•There is only one Milling Machine With this spesifications •Heavy & Large Fıxtures,• Because of small lot size Frequent Set-up Changıng, req.

WHY 4 AXIS MACHINE

DIFFERENT VIEWS FOR 4 AX MACHINE

6 Sigma

•Flexible Set-up Requırements, Geometric Differencies of the Fixtures •Group Technology Appl. diffuculties

For This Reason ; 4 axis Milling Machine were Selected to the Pilot Applicatıon.

•Due to 4 Axıs Milling Machıne Applıcatıon Results Wıll be Affected of Other Vertical-Horizontal and Multiple Axis Milling Machine Flexıbılıty Studıes...

6 Sigma

Fixture Handling from SRS

Fixture Cleaning

To the Machine

Machine Placement

Setup Control

Fixture Fastening

Part Handling

T nut, Fastener Finding

6 Sigma

Part positioning

FLOWCHART FOR SETUP

Internal S/U

External S/U

• WHY THE TIME IS INCREASING?• Dimensions and weights of the fixture

• Fix. Geometries haven’t standart Shapes

• Nonstandart Pın and Bolts slots & Holes

• Used Nonstandart Bolts

• Rotary Table Properties,

• Parts have different Datum Systems (Point ,area etc.)For this reason, there are very complex shape fixtures,

• Expanding fixtures

• T-Nut and Fastening Elements Problems

- Look for elements, Time requıred

6 Sigma

•As a Basement of Work;Fixtures will be fastened on machine as little as possible, No need positıonıng

•Fixtures and Machine datas are available; (Table-1)

Workıng Procedures 6 Sigma

•All Fixtures were layed out on Machine Rotary Table With Sub Plate. For this Reason Subplate Will be Designed & positioned with Pin-Bushing systems & Fastened to the fixture with Bolt-Nut

•Big Dimensions & Geometric Differencies and Datum Systems properties of Fixtures

• will be Controlled on Real/Right places

•Expanding Fixtures are some different Applications Requıred,

•Due to Set up reduction time works;

Workıng Procedures and troubles 6 Sigma

T-Nuts on the rotary table, -Bolts,Nuts Eye bolts will be placed near of the Machine These type of problems are caused increasing for Setup Times.

GENERAL VIEW OF FIXTURES

FIXTURES 6 Sigma

• We are working on the;

- Innovatıve and İmproved best Concepts Linear Bushing Systems

• One of the most important and innovative Equıpment are researching for Cleaning on the Machine Rotary Table

•Chips penetrated on the table, T-Nut channels, bolt holes and the other slots and holes.

•İnnovative cleaning, New easy cleaning Facility and Equıpments or;

•Chips may be holded without dropping These are researching for new innovation...

Workıng Procedures 6 Sigma

44" M39 fi xt .41" M37 F ixt .

TORK SHAFT F ixt

L OWER BEAM F ixt .

36" DÖNEL TABL A

AL T- PL AKA

ROTARY TABLE and 5 DIFFERENT PARTS FIXTURES ON THE TABLE

ROTARY TABLE and FİXTURE LAYOUT ON THE TABLE 6 Sigma

6 SigmaM39 Fixturing & Sub Plate section View

M39 Fixture & Sub Plate Assy.

AĞIRLIKLARAĞIRLIKLAR; FİKSTÜR;780 kg ALT TABLA; 289 kg.

6 Sigma

General View for Sub Plate 6 Sigma

GGG 60

6 SigmaGeneral View of SubPlate

LINEAR BUSHING SYSTEMS 6 Sigma

6 Sigma

• Machine datas,• Rotary table

• Course

• T NUT ChannelI

• Fixturing Datas• Geometry & Dimensions

• Holes

• Fixturing systems (EXP, Datum systems etc.).

• Define SEF systems• Designing Subplate

• Pın-bushing Systems Selectıon

• Design Pin-Bushing position of subplate-Fix. Assy

• Define Positıon and Tolerances

• Sub Plate properties• Weight

• Sub plate Strength Calculatıon

• Pin-Bushing stress analysis

• Fixture Pin & Nut Stress Analysis

• Sub Plate -Rotary Table Fastening Method.• T-Nut Channels• Sub plate/Rotary Table Assy Design

procedure 6 Sigma

SubPlate Material: GGG 60 - Spheroidal Cast IronWeight; 285 Kg.

TOTAL Max Load on Rotary Table; 1070Kg.

Materials 6 Sigma

Important Issues

• Subplate Dimensions and Position Tolerances (.0000-.0015)

• Pın-Bushing Application and Fixtures thickness Differencies,For this reason Pin-bushing Position,

• If using linear Bushing Systems, Big and heavy Fixtures will be damaged on roller Bushing. For this reason radial and axial loads and stress will be defined.

• Subplate -fixture fasteners like Bolt, Nut, Pin, eye bolt stress analysis

required

6 Sigma

SAVING• ALL PARTS HAVE 20 S/U /YEAR

• MİN %25 SAVING

• 30 HRS FOR M61 PARTS




• 16 HRS FOR L44815G01 PARTS

• TOTALLY 100 HRS/YEAR FOR 4 AXIS MACHINE

• 106*18=1908$

• FLEXIBLE SETUP AND OPERATOR SAVING

• RELAX SETUP

• APPROX % 50 SAVING FOR POSITIONING; NO NEED USE CLAMP, T-NUT etc. 5$ *25=125$

• OPERATOR ASSURANCE, SAFETY AND EASY SETUP

BB. : PLANNEDREV : OI COMPLETEDFW:61

HAZİRANSUBJECT RESPONSIBLE1 2 3 4 5 6 8 9 # # # # # # # # # # # # # # # #

1- OPERASYON ,TEZGAH VE FİKSTÜR DATALARININ TESPİTİ, ÖLÇÜMLER,FİKSTÜRLERİN PTEZGAH ÖNÜNDEDEĞERLENDİRİLMESİ 2-DELİKLERİN CIRCULAR EKSENLERİNİN TESPİTİNDEN SONRA BALL-LOCK ve/veya PİM P İLE YERLEŞTİRME KARARI , TAŞIYICI ASKI SEÇİMİ . . .

3- FİKSTURDEKİ BAĞLAMA DELİKLERİNDEN HAREKETLE SUB- PLATE TASARIMITEAM P

4-SUBPLATE İMALATI (DÖKÜM VE İŞLEMESİ), PİM-BURÇ İMALATI) ve TEDARİĞİTAKIM-KALIP P

5-FİKSTÜRLER BELİRLENDİKTEN SONRA İŞLEM SIRASINA GÖRE DELİNMELERİ VE BURÇ TK-KL/İMALAT PÇAKILMASI YERLEŞTİRİLMESİ

6-FİKSTURLERİN SUBPLATE İLE DENENMESİ , CNC PROGRAMLARININ PTADİLATI

MAYIS

PROGRAM PLAN FOR SETUP REDUCTION

OCAK ŞUBAT MART NİSAN

PROGRAM PLAN 6 Sigma

MeasureMeasure

Understand Environment- Meet business leader- Establish key contacts- Tour process- Identify process owner- Identify team members

Bound the Project

Identify Customer Requirements- CTQ’s via QFD- Identify additional data Needs

Evaluate measurement system- Gage R&R

Establish Product Capability- Calculate DPU- Calculate Z st and Zlt

Train Team on 6 sigma tools

Review Measure Phase- Champion comments- Update team / stakeholders


Process MapIdentify Variation Sources

Identify X’s- Cause & Effect Diagram

Analyze Data- Apply Statistical Tools- Hypothesis Tests

Review process mapDevelop new process flow

Identify Improvement Actionsand Implementation Plan

Implement Improvements--

Communicate Improvements

Develop Presentation- Review Team / MBB / Sponsor- Present results to Champions and Operational Leaders



Implement Control Systemfor Process Fixes

Develop Risk AssessmentRisk Abatement Plan

Revalidate Cause & Effect ofX’s to Achieve Y’s

Identify Opportunities forStandardization

List Best Practices and Identify Lessons Learned

Obtain buy-in / support for improvement actions

Issue Revised QCWIs /procedures where applicable

Review Analyze Phase- Champion comments- Update team / stakeholders

Review Improve Phase- Champion comments- Update team / stakeholders

Identify opportunities toleverage improvements



Define performance standards- Gather / Pareto data - Review Historical data

Screen Potential CausesIdentify Root Causesof variation

Establish Operating Tolerances

Determine Process Capability

Define Performance Objective for “Y”

Create Process MapBenchmark similar productsand processes


Coordinate with ITS for systemsresources where applicable

Identify Follow-up Action Planand Individuals Responsible

Hand off project to Process Owner

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

Create Product Tree

Define additional data needs

Collect & analyze data to validate improvement

Monitor process performance

ImproveImprove ControlControlAnalyzeAnalyze

Six Sigma Project Scorecard 6 Sigma

fast & easy machine setup project ( simply exchange of fİxture-sef ) &

Documents

machine tools

setup time reduced cycle

time requred

decrease of su time

reduced cycle time

nonflexible setup

project leader

project id