Category Archives: Kaizen

External Diameter Measuring Tool for Precision Pipe – CT-Effects Application Example

Inspected pieces:
585 pieces ⇒ 1,260 pieces (Increased by 675 pieces)

Productivity Improvement of Approx. 115%


Electronic Components 
External Diameter Measuring Tool for Precision Pipe
– CT-Effects Application Example
[ Robot/Electric Actuators ]
[ Controllers ]



[Equipment Detail]

  • An optical measuring tool moves along a pipe and measures the external diameter at a specific location (near center) of the pipe surface.

  • The cycle time was long and this was the bottle neck in the production line.

  • A pipe is placed and removed manually.


[Problem in Using an Air Cylinder]

  • The pipe length was 2,000mm, and the measuring action was activated by a sensor. As it was not possible to have a speed change on the way in order to obtain stability through constant speed operation, the instrument needed to have a low-speed operation through the whole stroke.

  • Line stoppage has occurred for 30 minutes a day due to measuring error.


[After Replacing to ROBO Cylinder]

    • Moving with high speed to the front of the measurement point, moving slowly to take measurement at the measurement point, then travel back to the home position with high speed enabled for shorter cycle time.

    • The measurement tool moves stably in constant speed, which ended with nearly 0 times of line stoppage due to measurement error.

    • By using the zone output signal, the sensor is no more needed.

    • Eliminating the bottle neck and improved the line productivity.


[CT Effects – Reduction in Cycle Time/Choco Tei]


Subject Instrument with Air Cylinder Instrument with Electric Cylinder 
Cycle Time 40 seconds/piece 20 seconds/piece
Duration of Line Stoppage 30 minutes/day 0
Number of Work Pieces inspected in Line Operation Hours 585 pieces (*1) 1,260 pieces (*2)

7-hour operation per day (420 minutes)
(*1) (420 minutes – Line Stoppage 30 minutes) *60 seconds/ 40 seconds/ piece=585 pieces
(*2)  420 minutes *60 seconds/ 20 seconds/ piece=1,260 pieces

See more IAI electric actuator application examples


Adhesive Applicator – CT-Effects Application Example

Production Amount per Day:
560 ⇒ 940 pieces: ⇒  Productivity Improvement of 68%


Electronic Components / Applicator
Adhesive Applicator – CT-Effects Application Example
[ Robot/Electric Actuators ]
[ Controllers ]
RCP2-SA7C (2 axes) PSEL


  • [Equipment Overview]

    An apparatus for applying an adhesive to the cover of lamp lights and an indicator light in the manufacturing of electronic components.

    X-axis: RCP2-SA7C
    Y-axis: RCP2-SA7C
    Z axis: ISB-MXL
    Dispensing of the adhesive: RCP2-RA10C


  • [Problems of the air cylinder used]

    1. They were dispensing the adhesive by using the air cylinder. The dispensing rate was changed because the air pressure was unstable and the adhesive was interrupted or lumped.
    2. The viscosity of the adhesive changes under the conditions such as temperature, so that it took time to adjust the dispensing pressure.
    3. Defective parts were made when the adhesive that attached to the work parts formed adhesive strings that weren’t cut off after dispensing.


  • [Benefits of the electric actuator]

    • The 45 seconds cycle time has been reduced to 30 seconds because the amount of adhesive dispensed always stayed stable.
    • This enabled the supply of adhesive to be stable all day after trial testing each morning.
    • The failure rate due to adhesive dispensing reduced to almost zero from about 10 pieces a day since they set movement to cut clean the dispensed adhesive. This movement was of the electric actuator in the vertical direction and the slide table.


[CT Effects – Reduction in Cycle Time/Choco Tei]


Project Comparison Equipment with the air cylinder Equipment with the ROBO Cylinder
Cycle Time 45 seconds 30 seconds
Duration of Choco-Tei per event 60 minutes / day 60 minutes / day
Production per day 560 pieces (*1) 940 pieces (*2)

(*1) When the air cylinder was used: (8 hours – 1 hour Choco-Tei) ÷ 45 seconds = 560 pieces per day
(*2) When the ROBO Cylinder was used: (8 hours – 10 minutes) ÷ 30 seconds = 940 pieces per day

See more IAI electric actuator application examples


CT-Effects Mini Webinar Video – Learn How to Reduce Production Costs and Get Huge Savings


Mini Webinar videos at:

Learn CT-Effects!, the key to reduce production costs. You may be able to further reduce the costs if you look closely at the CT effects. (This is for the environments of manufacturing, factory, automation, and much more.) So what exactly are CT effects? Check out the video clips!

[Short Video Titles]
CT Effect 2014 001 Intro – Key to Reduce Production Costs at Automation Manufacturer
CT Effect 2014 002 Productivity Improvement and Ceased Time Reduction
CT Effect 2014 003 Application Example of Cycle Time Reduction – Case Study
CT Effect 2014 004 Comparison Air Cylinder and Electric Actuator by Speed on t v Diagram
CT Effect 2014 005 Changeable Speed and Zone Output at Press Fitting Operation
CT Effect 2014 006 & 007 Cut The Costs Get The Huge Saving
(006: Reduce Machines Increase Production by using IAI Actuator ROBO)
(007: Cut The Costs Get The Huge Saving by IAI Electric Actuator)
CT Effect 2014 008 Example of Choco Tei Reduction & Huge Cost Saving LV
CT Effect 2014 009 Long Life Lower Inventory, Energy Cost & CO2Emissions, LV


IAI Electric Actuator: