1 hour minimum change over to 3 minute change over, (still in testing)

[Cordon]

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.

[Marc]

I hope you let us know how this proceeds. That's quite a reduction in change-over time.

[mike101338]

GREAT JOB!!!!!!!!!!!!
Hopefully this will catapult your organization into bigger and better things.

[Cordon]

Originally Posted by Marc

I hope you let us know how this proceeds. That's quite a reduction in change-over time.

The idea has been around for a while, the presentation broke the ice and all the help from the Cove made the presentation. Everyone here gave me a clear vision of what needed to be presented and how.

I will definitly keep everyone up to date with the progress.

[Randy]

So now what are you going to do with the other 57 minutes?

[Cordon]

Sorry I never updated on how it turned out; I was layed off in December and haven't been called back. Guess I pushed too many buttons with the owners!

[Claes Gefvenberg]

Originally Posted by Cordon

I was layed off in December and haven't been called back. Guess I pushed too many buttons with the owners!

Oh... Sorry to hear that, Cordon. So how are you doing these days?

/Claes

[sspoldir]

An hour down to minutes was a huge improvement... unfortunately in far too many old school companies it seems that the person who is gung ho change agent ends up on the chopping block.

Originally Posted by Cordon

Sorry I never updated on how it turned out; I was layed off in December and haven't been called back. Guess I pushed too many buttons with the owners!