Embed Size (px)
Citation preview
Automation & Robotic Arm:
Throughput and Capacity
Jim Stertz
Lowell Inc.
www.360mn.org
Automation and Robotic Arm:
Maximize Throughput and Capacity
Jim Stertz – Director of Quality / Technology
Quality Assurance Manager
Lowell, Inc.
Contents Property of Lowell, Inc. 2008
4
a contract manufacturer of precision machined, medical
device components and mechanical assemblies
Lowell, Inc. is . . .
About Lowell, Inc.
• Precision Machining Contract Manufacturer
• Brooklyn Park, MN - Founded in 1964
• Family-Owned
• 70 Associates Averaging 22.5 Years of Service
• ISO 9001:2008 & ISO 13485:2003
• 51,000 SF
Content property of Lowell, Inc. 2011 www.lowellinc.com 763-425-3355 [email protected]
About Lowell, Inc.
• Markets and Customers Served Medical
Cardiovascular 45%
Orthopaedic Implants 50%
Aerospace 5%
About Lowell, Inc. • Capabilities
Swiss Turning
Multi-Axis Milling
Mill/Turn
EDM
Laser Marking
Class 100 & 10K Clean Rooms
Development
Assembly
Class III Medical Device
Leitz Model PMM-C 700 12.10.7 Coordinate Measuring Machine Sub-micron Accuracy CMM 0.6 + L / 600 [um] MPE E 0.6 um MPE P 1.5 um THP Range: 1200 x 1000 x 700 (47”x 40”x 27.5”) ww PC-DMIS CAD++ software A climate controlled room constructed with a temperature variation of no more than .9° F per hour, per meter
Value Proposition •PMM C-700 uptime was 60% of 108 hours of potential capacity, we
needed more available time and throughput. Business Problem
•We added automation using advanced features of PC-DMIS and a robotic arm to tend the PMM and CMM Solution
•We average 150 hours of uptime per week with 2.5 associates, CMM programmer spends more time programming offline. Benefits
•Consistent available capacity and uptime, low direct labor costs Anticipated Long-Term
Benefits (optional)
•Adding robot pick and place to further reduce direct labor costs Future Plans/Strategy or
Summary Statement
12
Keep it Simple! Many tend to overcomplicate or over
simplify, we need balance.
Similar to leading people, use everyone to their strengths
-Robot -Hardware -Software -People
How it all started DEA Swift - 1995
Grid Pattern – uniform spacing Able to place multiple fixtures without removing or multiple parts
Steps to Automation
‘98 added Excel 7*10*7
‘06 converted to PC-DMIS
‘07 added offline PC-DMIS
‘08 added PMM-C 700
‘09 automation of PMM
‘10 integration of robot
‘13 added Global CMM
Scott, Peter and Brad 80% my ideas, 20% my work
Software Structure
VB Robot
PC-DMIS
Files and Folders
Robot - Motoman HP20
Automation is; 20% Robot 80% Process
Automation of PMM The machine must be automated first, most times this is
the most difficult step, and the most overlooked.
We started with 10 stations
Advanced PC-DMIS Concepts
Files
Serial Numbers
Point Clouds
While / Case
Job Numbers - traceability
Pallets, Grippers and Fixtures
Standard Carrier Identification Device
Multiple Parts
PC-DMIS File Read / Write DATA1 =FILE/OPEN,G:\QA\PMM\PALLET SERIAL NUMBERS\SN_IO756.TXT,READ
END_IF/
760 =LABEL/
IF/IDSPUDCIR1.DIAM<.761 AND IDSPUDCIR1.DIAM>.759
DATA1 =FILE/OPEN,G:\QA\PMM\PALLET SERIAL NUMBERS\SN_IO760.TXT,READ
END_IF/
FILE/CLOSE,FPTR,KEEP
PC-DMIS Counters / Multiple Parts
WHILE/CNTR<6
ONERROR/PROBE_MISS,GOTO MISS PRB END
PC-DMIS Serial Numbers
V3 =FILE/READLINE,DATA1,"PART: "+{PARTSN}
COMMENT/REPT,
"SN: "+PARTSN
TRACEFIELD/NO_DISPLAY,LIMIT=15 ; Serial
Number : PARTSN
PC-DMIS Point Clouds
ASSIGN/V5=PARTSN ASSIGN/V1="G:\QA\PMM\THISTLE\1BAT2 259ET H89PNG\SMART PROFILE
EXPORTS\ " +V5 + ".XYZ" COP1 =COP/DATA,SIZE=1527, FINDNOMS=NO,REF,SCN1,SCN2,.160 212,.160 2 212,.160 3
212,PNT1,PNT2,PNT3,PNT4,PNT5,PNT6,PNT7,PNT8,PNT9,PNT10,PNT11,PNT12,PNT13,PNT14,PNT15,PNT16,PNT17,PNT18,PNT19,PNT20,PNT21,PNT22,PNT23,PNT24,PNT25,PNT26,PNT27,PNT28,PNT29,PNT30,PNT31,$
PNT32,PNT33,PNT34,, COPOPER1 =COP/OPER,EXPORT,FORMAT=XYZ,FILENAME=V1,SIZE=1527 REF,COP1,,
Pallets, Grippers and Fixtures
Standard Carrier
In Bay / Out Bay Priorities
Next High Low
Storage Rack
Automatic Vise
Cost of Automation
Robot at rest > 80% of the time
Additional CMM Moves
Throughput not cycle time, about 2.5 minutes to change a pallet and start inspecting the next part
Trying to do too much, there is a limit, can’t eliminate human interaction
Cost to Automate
Software = $3,000 Robot = $54,000 Integration = $80,000 Hardware = $10,000
$147,000
Cost to not Automate
Minimum of two associates = $80,000/year Second PMM = $425,000
Robot Motoman HP20
Cost = $54,000 Life expectancy at full motion = 20 years Work hours per week = 168 Vacation days = 0 Sick days = 0
Did not eliminate any jobs, it helped save 70 jobs
Single Bone Screw
Bone Screws
Reduced Throughput time 40% - 70%
Show Robot AVI here
Keep it Simple!
Many tend to overcomplicate or over simplify, we need balance.
Thank You
Questions & Comments
