6 Sigma
FAST & EASY MACHINE SETUP PROJECT
(SIMPLY EXCHANGE OF FİXTURE-SEF ) &
PILOT APPLICATION OF 4 AX MILLING MACHINE
Mümtaz ERDEM
PROJECT SUMMARY
6 Sigma
Project Y
- PRODUCTION
Project
Description
SEF-Simply Exchange of Fixture and Pilot Application
on 4 Axis Machine
Project
Objectives/Goals
Production Flexibility and Decrease Setup Time
Customer/GE
Benefits
•Reduced cycle time/improve capacity
Financial Benefits
Y Owner
MBB/BB
Project Title: Create an order to get tool,
Project ID#: -
Six Sigma Project Status
fixture, gage, and cnc program in digitam system
Status as of: Measure-Analyze
Expected Completion Date:
Project Leader:
Y Owner:
Project Y: PRODUCTIVITY
Financial Benefits:
Project Statement & Benefits
MMEASURE ANALYZE
Scope:
•
Goals & Objectives: Flexibility on production
Decrease Setup Times
•
Benefits: Reduced cycle time / Improve capacity
Status
•
•
•
Accomplishments: Data gathering, fixture and
Machine
Tools applied:
Significant findings:
CONTROL
Team Members
Name
•
IMPROVE
Function
BLACK BELT
BLACK BELT
SUPR.TOOL
GREENBELT
GREENBELT
SUPERVISOR .
SUPERVISOR
TOOL STOCKKEEPER
12345678-
Next Steps
•
Next steps:
•
•
Additional tool to be applied: Design system &
Help needed: Yes
CTQ’s - Defect - Target
6 Sigma
CTQ
HIGH SET-UP TIME, NONFLEXIBLE SETUP
Defect
STANDARDISATION
Target
25% DECREASE OF S/U TIME & MORE FLEXIBILITY
6 Sigma
4 AXIS / 36" PART NO OP. NO SET-UPRUN TIME N FIX NO
MOUNT RING 1364M37G02 65 - 70 1,8
33.21 1 M91554
1364M37G02T
196 1
2
MID GUTTER 1807M62P01
10 1,3
1,91 2 TEI 2764
FORWARD RING1964M52P05
130 1
1,39 3 M93015
LOWER BEAM 9348M61P01
3 0
2,35 4 TEI 1964
115 2
2,03
ACT.RING 9539M39G04
150 1,5
10,15 5 M91644
170 0,5
2,03 6 M91645
#7 BRG. HOUSINL14405P02
G
70 1,5
3,2 7 M91057
TORK SHAFT L44815G01
105 0,5
3,8 8 M92420
#4 BRG. HOUSIN9646M10P03
G
60 0,3
3,3 9 M91102
FİXTURE GEO.
FIX.DIA.
D
41"x 2.25
D
D
P
24" X 2.5"
38" X 1.5" exp.
D
D
D
P
D
44" x 4
44 x 3"
28"X7"
FIX DIM(aXb) ALT.MACH
MCB1210/MC98
22"x7.5"x1"
MCB1210/MC98
41 "x 10" x1.5 "
26"X8"
TABLE-1 MACHINE-FİXTURE & OPERATION DATAS
MCB1210/MC98
6 Sigma
80000
70000
60000
50000
40000
30000
20000
10000
0
1.
qu
ar
te
r
OPTIME
S/U TIME
6 Sigma
OPERATION & S/U TIME RELATIONSHIP
35
30
25
20
OP
S/U
15
10
5
0
M37
M52
M61
M39
L44815
CAUSE AND EFFECT
6 Sigma
OPERATOR
TRAINING
SHIFT
FASTENİNG MAT’L
CARELESSNESS
High S/U
Hours
STANDARDIZATION
FLEXIBLE
CHANGING
FIXTURE
CHIP CLEAN
METHODS
EQUIPMENT
WHY 4 AXIS MACHINE
b
6 Sigma
•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.
GENERAL VIEW OF THE 4 AX MILLING MACHINE
6 Sigma
•Flexible Set-up Requırements,
Geometric Differencies of the
Fixtures
•Group Technology Appl.
diffuculties
DIFFERENT VIEWS FOR 4 AX MACHINE
6 Sigma
•Due to 4 Axıs Milling Machıne Applıcatıon Results Wıll be
Affected of Other Vertical-Horizontal and Multiple Axis
Milling Machine Flexıbılıty Studıes...
For This Reason ; 4 axis Milling Machine were Selected to
the Pilot Applicatıon.
FLOWCHART FOR SETUP
Fixture
Handling from
SRS
Fixture
Cleaning
To the
Machine
Machine
Placement
Internal S/U
Fixture
Fastening
Part Handling
Part
positioning
External S/U
6 Sigma
T nut,
Fastener
Finding
Setup
Control
6 Sigma
• 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
Workıng Procedures
•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)
6 Sigma
•All Fixtures were
layed out on Machine
Rotary Table With
Sub Plate. For this
Reason Subplate Will
be Designed &
positioned with PinBushing systems &
Fastened to the
fixture with Bolt-Nut
Workıng Procedures and troubles
•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
T-Nuts on the rotary table,
works;
-Bolts,Nuts Eye bolts
6 Sigma
will be placed
near of the Machine
These type of problems are caused
increasing for Setup Times.
FIXTURES
GENERAL VIEW OF FIXTURES
6 Sigma
Workıng Procedures
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...
ROTARY TABLE and FİXTURE LAYOUT ON THE TABLE 6 Sigma
AL T - PL AKA
4 1" M3 7
F ix t .
4 4 " M3 9 f ix t .
T ORK SHAF T
F ix t
L OWER BEAM
F ix t .
3 6 " DÖNEL
T ABL A
ROTARY TABLE and 5 DIFFERENT PARTS FIXTURES ON THE TABLE
M39 Fixturing & Sub Plate section View
6 Sigma
M39 Fixture & Sub Plate Assy.
AĞIRLIKLAR;
FİKSTÜR;780 kg
ALT TABLA; 289 kg.
6 Sigma
General View for Sub Plate
6 Sigma
General View of SubPlate
GGG 60
6 Sigma
LINEAR BUSHING SYSTEMS
6 Sigma
6 Sigma
procedure
• 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
6 Sigma
Materials
6 Sigma
SubPlate Material: GGG 60 - Spheroidal Cast Iron
Weight;
285 Kg.
TOTAL Max Load on Rotary Table;
1070Kg.
Important Issues
6 Sigma
• 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
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
PROGRAM PLAN
6 Sigma
PROGRAM PLAN FOR SETUP REDUCTION
BB. :
PLANNED
REV : OI
COMPLETED
FW:6
1
SUBJECT
OCAK ŞUBAT
MART
NİSAN
MAYIS
HA
RESPONSIBLE
1 2 3 4 5 6
8 9 # # # # # # # # # # # # # # #
1- OPERASYON ,TEZGAH VE FİKSTÜR DATALARININ TESPİTİ, ÖLÇÜMLER,FİKSTÜRLERİN
TEZGAH ÖNÜNDEDEĞERLENDİRİLMESİ
2-DELİKLERİN CIRCULAR EKSENLERİNİN TESPİTİNDEN SONRA BALL-LOCK ve/veya PİM
İLE YERLEŞTİRME KARARI , TAŞIYICI ASKI SEÇİMİ
. . .
3- FİKSTURDEKİ BAĞLAMA DELİKLERİNDEN HAREKETLE SUB- PLATE TASARIMI
TEAM
4-SUBPLATE İMALATI (DÖKÜM VE İŞLEMESİ), PİM-BURÇ İMALATI) ve TEDARİĞİ
TAKIM-KALIP
5-FİKSTÜRLER BELİRLENDİKTEN SONRA İŞLEM SIRASINA GÖRE DELİNMELERİ
TK-KL/İMALAT
VE BURÇ
ÇAKILMASI YERLEŞTİRİLMESİ
6-FİKSTURLERİN SUBPLATE İLE DENENMESİ , CNC PROGRAMLARININ
TADİLATI
P
P
P
P
P
P
Six Sigma Project Scorecard
Measure
Understand Environment
- Meet business leader
- Establish key contacts
- Tour process
- Identify process owner
- Identify team members
Bound the Project
Train Team on 6 sigma tools
Create Product Tree
Identify Customer Requirements
- CTQ’s via QFD
- Identify additional data Needs
Create Process Map
Coordinate with ITS for systems
resources where applicable
Define performance standards
- Gather / Pareto data
- Review Historical data
Evaluate measurement system
- Gage R&R
Establish Product Capability
- Calculate DPU
- Calculate Z st and Zlt
Develop Presentation
- Review Team / MBB / Sponsor
- Present results to Champions
and Operational Leaders
Analyze
Improve
6 Sigma
Control
Review Measure Phase
- Champion comments
- Update team / stakeholders
Review Analyze Phase
- Champion comments
- Update team / stakeholders
Review Improve Phase
- Champion comments
- Update team / stakeholders
Train Team on 6 sigma tools
Train Team on 6 sigma tools
Train Team on 6 sigma tools
Define Performance
Objective for “Y”
Review process map
Develop new process flow
Process Map
Identify Variation Sources
Screen Potential Causes
Identify Root Causes
of variation
Identify X’s
- Cause & Effect Diagram
Establish Operating Tolerances
Issue Revised QCWIs /
procedures where applicable
10%
20%
Revalidate Cause & Effect of
X’s to Achieve Y’s
Determine Process Capability
Implement Control System
for Process Fixes
30%
40%
Benchmark similar products
and processes
Identify Improvement Actions
and Implementation Plan
Analyze Data
- Apply Statistical Tools
- Hypothesis Tests
Develop Risk Assessment
Risk Abatement Plan
Identify Opportunities for
Standardization
Obtain buy-in / support for
improvement actions
List Best Practices and
Identify Lessons Learned
60%
Implement Improvements
Collect & analyze data to
validate improvement
Identify opportunities to
leverage improvements
70%
Define additional data needs
Develop Presentation
- Review Team / MBB / Sponsor
- Present results to Champions
and Operational Leaders
Communicate Improvements
Develop Presentation
- Review Team / MBB / Sponsor
- Present results to Champions
and Operational Leaders
Identify Follow-up Action Plan
and Individuals Responsible
50%
Hand off project to
Process Owner
Develop Presentation
- Review Team / MBB / Sponsor
- Present results to Champions
and Operational Leaders
80%
90%
Monitor process performance
100%