Nissan Part Fabrication Maximizing Throughput Executive Summary Project to increase throughput, profits, and reducing lead time. Favorable results: Increased production capacity by 322,080 pcs per year. Increased annualized profit of current production demand $62,200. Increased Profits total $195,032 Reduced machining cost by est. $4000.00 per year. Reduced 16hrs of production per week. Team Members: Project Lead: Eric Mosley Assistant: Michael Logan Date:11/11/13
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Nissan Part Fabrication
Maximizing Throughput
Executive Summary Project to increase throughput, profits, and reducing lead time.
Favorable results:
Increased production capacity by 322,080 pcs per year.
Increased annualized profit of current production demand $62,200. Increased Profits total $195,032
Reduced machining cost by est. $4000.00 per year. Reduced 16hrs of production per week.
Team Members:
Project Lead: Eric Mosley
Assistant: Michael Logan Date:11/11/13
Eric
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Reason for Selection
Improve Inventory It has become crucial for the shop floor to remain as spacious as possible yet we must keep our inventory
minimum requirement fully stocked at all times. Reducing cycle times reduces WIP inventory that is stored
on the shop floor.
Shrinking the Herbie There are several processes that a bed rail must pass through to become a finished part. Of all these
processes the VMC’s stand as the “Herbie” with other processes being 3-8 times faster . It was time to see
what could be done to ease the required buffering. Keep machine running non-stop for 8hr shifts.
Increasing Throughput We are currently quoting our customer for more work (double current orders). Our customer demands a
good price. By studying and improving current process flow we will be in a better position to know our costs
and needs to take on the additional work and offer more competitive pricing
Increasing Profits With the customer always demanding a competitive price and our needs to be more profitable we must find
ways to increase profits without increasing our prices. Reducing the time and costs to make the customers
part gives us the ability to meet both external and internal demands.
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$ Reduce Machine Wear and Costs Reducing Cycle times Reduces the odds of working the machine over typical hours to complete an order.
A reduced cycle time equates to more parts in less time resulting in less wear per part. Using Programming
techniques such as “smoothing” to reduce cycle times and wear by minimizing impact movements.
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Targets
Reduce Machine Cycle Times by 15%
Reduce Machine Setup Times by 25%
Increase profits by 25%
Reduce Machine Wear and Mechanical downtime
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Reduce work hours by 15% 6
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Machining Concepts
New Tool Path
Old Tool Path
Tool overlaps paths and machine must start stop constantly. Redundant path overlapping is inefficient and start stopping is bad on machine components and negatively effects machining speeds.
Tool path does not overlap itself. All paths are forward progress. No unnecessary start/stops. Tool path is “smoothed” allowing higher machining speeds, much lower impact movements and less wear on machine components.
Tool Path: “Linear Ridged” Previous Method
Tool Path: “Curved Smoothing” Improved Method
By designing the tool path to be a continuous “line” for a longer distance the machine has more ability to
reach max velocity. By designing the tool path with less start/stop points you decrease the need to rely on
machine acceleration. This alone reduces machine wear as it is not trying to stomp the brake and mash
the gas as often. This overall reduces the need to rely on VMC ACC/VO Curve and decreases cycle times.
Reduce Setup Times, Increase Quality
Eliminate Sub-programs
Sub-programs, though useful can also be cumbersome and difficult to manage. The ability to edit or problem solve can be more time consuming. With Sub-programming it is more susceptible to have a corrupt file and machine crash.
Simplistic File Structure
By Eliminating Sub-programs there is no longer multiple programs to make up one complete program. Before there were 4-5 files to make one full program. Now there is simply one file to keep up with.
Use Digital Edge Finder
Digital Edge Finder removes most of the human error and guess work out of Work Offset setups. The operator simply drives the probe to the material till the LED lights. Traditional Edge finders require more knowledge to use, take more time to set offsets and are more prone to inaccuracies.