Transcript a1.ppt
g RotoBreak Cassette Assembly Station Optimization By Randy Greenberg SMA Due Date: 12/14/99 g RotoBreak Objectives: • Produce 1000 cassette assemblies per week for each of 3 worldwide locations • Use common processes and procedures for interchangeability • 40 hour work week • 75% location utilization g RotoBreak Measure of success: • 1000 units per week • Maintain 40 hour shift • 75% location utilization g RotoBreak Schedule: • Data collection 11/01/99 • Working model with recommendations 12/7/99 • Validation of model 2/15/00 • Revision to model 3/15/00 g RotoBreak Product description: Cassette module used in circuit breaker to make and break the circuit Key components are: 1.Cassette housing 2.Rotor 3.Contact arm 4.contacts 5.Straps 6.Springs 7.Pins 8.Arc chute 9.Ablative material 10.Links g RotoBreak Simulation layout • Work area breakdown Welding Line and load strap T(59,63,72) Contact arm welder T(95,110,130) Staking Second link to contact arm T(40,50,61) Molding Cassette Deflasher T(310,345,400) Arc chute assembly Arc chute T(57,64,75) Assembly Rotor assy T(65,71,82) Strap to cassette T(67,71,90) Arc chute insulation and rotor to cassette T(95,105,110) g RotoBreak Initial Layout g RotoBreak Results-first run •383 units output •Run for 37.5 hours •deflash bottleneck •Double number of deflash stations g RotoBreak Initial run output Percent utilization-inital run Cassette deflasher station location Arc chute insulation and rotor to cassette Strap to cassette Rotor assy Second link to contact arm staker Arc chute assy contact arm welder Line and load strap welder 0 20 40 60 % util. 80 100 g RotoBreak Results-First modification • 766 units output • Deflash still bottleneck • Add third station g RotoBreak First modification run Percent utilization-first modification Cassette deflasher station location Arc chute insulation and rotor to cassette Strap to cassette Rotor assy Second link to contact arm staker Arc chute assy contact arm welder Line and load strap welder 0 20 40 60 % util. 80 100 g RotoBreak Results-Second modification •Output 1000 units •Strap to cassette utilization only 65% •Combine ablative material with strap to cassette location •Transfer 20 seconds to this station g RotoBreak Second Modification output Percent utilization-second modification Casset t e def lasher st at ion location Arc chut e insulat ion and rot or t o casset t e St rap t o casset t e Rot or assy Second link t o cont act arm st aker Arc chut e assy cont act arm welder Line and load st rap welder 0 10 20 30 40 50 % util. 60 70 80 90 100 g RotoBreak Final results • Utilization greater than 75% • combine rotor and second link to contact arm staker g RotoBreak Final Results Percent utilization-third modification Cassette deflasher station Arc chute insulation and rotor to cassette location Strap to cassette Rotor assy Second link to contact arm staker Arc chute assy contact arm welder Line and load strap welder 0 20 40 60 % util. 80 100 g RotoBreak Conclusion • Capable of meeting goal of 1000 units per week • Need to add two additional deflash stations • Combine rotor and second link to contact arm staker operations