Category Archives: Productivity Improvement

Application Examples, CT-Effects, Kaizen, Productivity Improvement, Reduce Cost

Potting and Encapsulation Machine – CT-Effects Application Example

Here is an example of how to reduce labor costs and increase production by automatizing the electronic encapsulation process using the Table Top type robot TTA series, which was conducted manually previously.

Labor Cost:
Reduction of $22,300/year (*1)

Production Amount:
640 pieces/day ⇒ 740 pieces/day (Increased by 100 pieces/day) ⇒  Productivity Improvement of 68%


*Exchange Rate: 1(USD)=100(Japanese Yen)

 

Electronic Components / Applicator
Potting and Encapsulation Machine – CT-Effects Application Example
[ Robot/Electric Actuators ]
 [ Controllers ]
TTA-A3 Built-in

 

  • [Equipment Overview]

    Set a pallet on the equipment and press the start button on the TTA. The equipment starts applying a molding encapsulant on the PCB (printed circuit board) one by one to seal them up.

     

  • [Detail of the Work Process]

    1. The work piece is a PCB (printed circuit board) which is placed on a pallet. (20 work pieces for 1 pallet)
    2. Since the application process was conducted manually before introducing the equipment, it took 36 seconds for one work piece.
    3. It takes 3 minutes (180 seconds) to replace the pallet (operation time to remove the pallet, set a new one and then press the start button).

 

  • [Effect after Automatizing]
    • A molding encapsulant gets applied evenly in minimum time for the necessary amount, which made the operation time 30 seconds on average per work piece.
    • Since the worker is now only responsible for “the placement and removal of the pallets” and “to press the start button”, the person in charge of other duties can now handle this operation as well, which reduced the labor cost for workers who performed application.

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

 

Subject Manual Work Equipment with TTA
Cycle Time 36 seconds/piece 30 seconds/piece
Production Amount per day in Unit of pallets 32 Pallets(*2) 37 Pallets(*3)
Production Amount per day (Amount in unit of pallets 20 pieces/pallet) 640 pieces 740 pieces
Labor Cost per day $120/day(*4) $27/day(*5)
Labor Cost per Year (Labor cost per day *240 working days) $28,800/year Approx.$6,500/year

(*1) $28,800-$6,500. Subtracting automatizing cost in the 1st year will give $22,300 subtract TTA, machine, and program cost.
(*2) 28,800 seconds (operation time per day)/(36 seconds/piece *20 pieces/pallet + Pallet replacing time 180 seconds)=32 pallets=> Number of pallet replacing is 31 times
(*3) 28,800 seconds/(30 seconds/piece *20 pieces/pallet + pallet replacing time 180 seconds)=37 pallets=> Number of pallet replacing is 36 times
(*4) Labor $15/hour, 8hours/day
(*5) Total working time per day for pallet replacing=Time for pallet replacing 3 minutes. *Pallet replacing 36 times=108 min.(=1.8 hours), Labor cost=$15/hour, 8hours/day

*Exchange Rate: 1(USD)=100(Japanese Yen)

See more IAI electric actuator application examples

 

Application Examples, CT-Effects, Kaizen, Productivity Improvement

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 ]
ISPB-LXMX

XSEL-P/Q/J/K
SSEL
SCON

 

[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

 

Application Examples, CT-Effects, Kaizen, Productivity Improvement

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
RCP2-RA10C PCON-CFA
ISB-MXL XSEL

 

  • [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