Robotic Pad Printing Work Cell

2024 IE

The objective of this project is to create solid model of the final assembly & prospective gripper fingers, perform a time study & determine the marginal values of the metric required, generate the BOM & finalize a cost estimate, recommend a gripper, accumulation table, & desired UR (Universal Robot) robot for process, perform PFMEA to capture risks & identify mitigation, lastly, simulate the full assembly & the dynamic movements involved within the process to exact target values to each metric for our final design of the work cell.

Team Members

Evan Snyder | Keith von Volkenburg | Naoki Iwata | |

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Project Summary

Overview

The pad printing & etching stations are two separate processes highly dependent on manual labor to execute & limited by shift times, breaks, & other idle times. This leads to a lack of productivity & machine utilization, an excess number of products in WIP status awaiting processing. These products carry a handling cost and create an unsafe work environment (i.e., tripping hazards).

Objectives

  • Create solid model / drawings of the final assembly & prospective gripper fingers,
  • Perform a time/movement study and create a VSM (Value stream map) and determine the marginal values of the metric required.
  • Generate the bills of materials to finalize a cost estimate.
  • Recommend a gripper, accumulation table and desired UR (Universal Robot) robot for process.
  • Perform PFMEA (Process Failure Mode and Effects Analysis) to capture risks and identify mitigation.
  • Simulate the full assembly and the dynamic movements involved within the process to exact target values to each metric for our final design of the work cell.

Approach

  • Met with sponsor / experts to understand objectives and to align on clear standard & timeline
  • Setup several visits to Superior tire to tour facility & collect data
  • Several concepts for each component of design were considered & selected optimal pieces
  • Created a work cell design which we modelled on Inventor®
  • Designed a bracket prototype for the guiderail for the conveyor
  • Utilizing Simio® to test the system, we validated throughput and defect ratios
  • Collected processing time of 100-mins for 150 wheels with a defect rate of only 4.6%

Outcomes

Finally, the project was able to achieve several positive outcomes for Superior Tire and Rubber:

  • The sponsor will save $8000+ as a result of this project
  • This project led to the ability for the operator to be able to setup station & run it while tending to other responsibilities
  • The project created continuous product movement that increased productivity
  • The project resulted in a new innovative design that was tested using simulation software