Mini Webinar videos at: https://www.youtube.com/playlist?list=PLKoah4afs0KZGh94bwrZy9rrz0pktfIJ9
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: http://intelligentactuator.com
This process carries a pair of parts, and then does spot welding in 3 locations per part. Until now, because it was done manually, more workers were needed to increase production to meet customer demand. In addition, since the project of high-mix low-volume production has been increasing in recent years, the welding process was automated using our ROBO Cylinders this time. It cost $12,000 ($6,000 / unit × 2 units) to build the two units, but it was amortized over 7.5 months.
(Personnel Expenses was calculated at $10 / hour)
After changing to ROBO Cylinder
Due to the manual labor, large differences had come out in production volume and quality depending on the workers. But with the result of the automation, since the parts stop at the same location repeatedly for welding, the quality is stable, and the defects became almost zero.
Compared to the manual labor, cycle time is improved, and production has increased significantly.
Since the worker was now only responsible for the placement and removal of the parts, and they can now handle the two units alone, the labor cost is now half.
In a system for performing the alignment of some resin blocks, the ROBO Cylinder was adopted. The company’s products include designer plates to be used on the floor of a house by bonding resin blocks.
Previously, an air cylinder was used, this was changed to ROBO Cylinder which improved the cycle time and reduced the occurrence of Choco-Tei events.
When air cylinder was used
Because the resin blocks were misaligned by the impact of the air cylinder stop, they were operating it at a reduced speed. However, Choco-Tei was still occurring about 10 times a day because of the misalignment due to unstable speed. To rearrange the resin block and to recover from Choco-Tei, it took about 1 minute.
After changing to ROBO Cylinder
By replacing air cylinder to ROBO Cylinder, and adjusting the pressing force and acceleration/deceleration, they could increase the operating speed while minimizing the impact at the time of stop. In addition, Choco-Tei was reduced to near zero.
Heat Exchanger Hole Size Confirmation Application Example
Robot
TT-A3-4040
Controller
Built-in SEL controller
The process of checking the sizes of the holes in a heat exchanger is a successful example of reducing labor costs by shortening the cycle time.
The heat exchanger is an aluminum plate of 1mm thickness that has 900 vacant holes. The pitch of the 4mm diameter holes needs to be accurate. If the hole position deviates from this fixed pitch distance, failure will occur when passing the piping through the holes in the subsequent manufacturing process step.
Previously, the holes were visually inspected by a person one by one which took 45 minutes to test an entire heat exchanger.
As a result of switching to the tabletop robot to perform this inspection process, the operator can perform other duties after pressing the button to start the robot.
The labor costs to produce 20 units reduced from $270 to only $31 thus saving $57,460 a year in labor costs.
