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6 Sigma. FAST & EASY MACHINE SETUP PROJECT ( SIMPLY EXCHANGE OF FİXTURE-SEF ) & PILOT APPLICATION OF 4 AX MILLING MACHINE. PROJECT SUMMARY. 6 Sigma. Project Y Project Description Project Objectives/Goals Customer/GE Benefits Financial Benefits Y Owner MBB/BB. - PRODUCTION. - PowerPoint PPT Presentation
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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
• 20 HRS FOR M39 PARTS
• 20 HRS FOR M37 PARTS
• 20 HRS FOR M52 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
Train Team on 6 sigma tools
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
Train Team on 6 sigma tools
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
Develop Presentation- Review Team / MBB / Sponsor- Present results to Champions and Operational Leaders
Develop Presentation- Review Team / MBB / Sponsor- Present results to Champions and Operational Leaders
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
Train Team on 6 sigma tools
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