Cordon
21st July 2006, 08:21 AM
Well I just had to share this. Earlier this year we had gone through Dale Carnegie a training class and for the final project we had to come up with a project that would save the company at least $30,000 a year. The idea that I had was and old and proven one, the right tool for the right job. The good thing about the presentation is that the Board of Directors was there to listen and after hearing it they wanted it proven.
Currently we use adjustable fixturing for our studing welding robots which is a pain but the cost of the fixtures is cheap. We have 3 fixtures per table and 3 tables per robot with the capability of running up to 24 parts total. The thought is to have dedicated fixtures for high volume parts although cost was the down fall. Adjustable fixtures run about $150 compared to $750 for dedicated fixtures.
Origanally I wanted to make all the new fixtures in house but we quoted the parts out and it was a lot cheaper. For the bottom fixtures we have them laser cut which is perfect because they get a nice case depth which will prolong the life of the fixtures ($150). For the top fixtures we had them cut on a abrasive water jet and then had them finished machined to the desired tolereance ($200). Had to buy new anti-rotation air cylinders ($200) and some in house finish work to put every thing together ($200).
The end results of the test was staggering, where it would take a minimum of one hour to do a change over for one fixture we can do it in 3 minutes! We ran 1 part on one of the new fixtures, changed everything over, changed the program on the robot and ran another part all in three minutes, 2 completely different parts in 3 minutes! We did a 3 part test in 7 minutes.
Now granted that we only have one set of each for the different family of parts and conditions were perfect for this change over, everyone is very pleased. We are still in the testing stage and are hoping to have it finished soon, my plan is to have 2 tables ready to go by December.
Many thanks go to our CAD guy, robot leader and our machinist. For our estimated savings we divided it by 4 for the presentation so the Board would bit on it ($35,000).
Last but not least I need to thank all of you here for the help and advice you gave me in a previous thread that related to this very subject. :thanx:
Currently we use adjustable fixturing for our studing welding robots which is a pain but the cost of the fixtures is cheap. We have 3 fixtures per table and 3 tables per robot with the capability of running up to 24 parts total. The thought is to have dedicated fixtures for high volume parts although cost was the down fall. Adjustable fixtures run about $150 compared to $750 for dedicated fixtures.
Origanally I wanted to make all the new fixtures in house but we quoted the parts out and it was a lot cheaper. For the bottom fixtures we have them laser cut which is perfect because they get a nice case depth which will prolong the life of the fixtures ($150). For the top fixtures we had them cut on a abrasive water jet and then had them finished machined to the desired tolereance ($200). Had to buy new anti-rotation air cylinders ($200) and some in house finish work to put every thing together ($200).
The end results of the test was staggering, where it would take a minimum of one hour to do a change over for one fixture we can do it in 3 minutes! We ran 1 part on one of the new fixtures, changed everything over, changed the program on the robot and ran another part all in three minutes, 2 completely different parts in 3 minutes! We did a 3 part test in 7 minutes.
Now granted that we only have one set of each for the different family of parts and conditions were perfect for this change over, everyone is very pleased. We are still in the testing stage and are hoping to have it finished soon, my plan is to have 2 tables ready to go by December.
Many thanks go to our CAD guy, robot leader and our machinist. For our estimated savings we divided it by 4 for the presentation so the Board would bit on it ($35,000).
Last but not least I need to thank all of you here for the help and advice you gave me in a previous thread that related to this very subject. :thanx:
