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Lean Automation Equipment from Concept to Machine

Thursday, May 13th, 2010 by ksmith

Being in marketing has its advantages.  I get to watch our engineers work on complex projects every day and since I am the one that puts movies together, I decided it would be cool to watch them go from a clean sheet design through to the machine being assembled by the shop.  When the engineers started working on a concept for a new machine I took pictures every day of the white boards where they were sketching out their designs.  They start here so that they don’t have to keep going back and changing a model in SolidWorks.  Then when they did start to design on the computer, I had the lead designer take a picture every day of the machine.

It was really cool to see the design changes that resulted in a much more compact design than the original idea that they started out with.  After the machine was fully designed I hooked up a camera to take pictures at intervals throughout the day to watch our assembly crew put each component onto the table and see the machine come to life.

This clip takes a machine from concepts on a white board through design and build of a machine.   I hope you enjoy it.

Machine Assembly - What Works Best

Thursday, July 30th, 2009 by Ken

After working in a shop for over 30 years, I have found that following a process when it comes to assembling a machine works the best. 

First, it always helps to sit down with the designer and find out what kind of things to watch for, such as customer constraints or hazardous locations etc.  It is a must to have a complete print package before you start to assemble.  You need to look it over to find the best place to start. 

Subassemblies can be built and then installed on the machine later when the longer lead time items come in.  Most of the time the parts that come in first will be electrical and small parts for subassemblies; this allows you to assemble and wire without having the rest of the machine.

Next, look for assembles that can be built that won’t have to be disassembled in order to install on the machine.  This will help cut down on the time spent on assembly.  I also recommend you build the subassemblies with wire labels and air lines marked for faster install.  You can adjust slides and set sensors on the bench to save even more time.

Once you have the machine base and table top, look for the best way to route the wires and air-lines and drill holes for tie wrap bases or other mounting plates.  Then start installing the subassemblies at the center and work your way out, be sure to tighten all fasteners and check the fit of moving parts.

When all the subassemblies are installed with sensors and air lines ran, it’s time to do the I.O. check out manually then check them through the P.L.C.  Once I.O. is complete you can start to de-bug and run the machine.

The Four Day Work Week is Here to Stay

Tuesday, November 11th, 2008 by Roger

A few months ago Setpoint moved to a 4 day work week.  The plan was to run it as an experiment for 90 days and see how things worked out.  I’m pleased to report the experiment has been a rousing success and that we intend to continue on with virtually our entire workforce on a 4 day, 10 hours per day schedule, Monday through Thursday.

The feedback from our team members has been extremely positive, as everyone has settled into routines of spending most Fridays with their families or enjoying their hobbies.  There are of course exceptions to this.  We have been in a busy cycle for the last 8 weeks or so and have had many people working on Fridays in order to meet our obligations to our customers.  But even with a day of overtime on Friday’s we’ve usually been able to take off Saturdays and Sundays for two-day weekends.  Morale is up, productivity is up.

We did spend some considerable time and effort upfront to alert our customers to our plans regarding the 4-day week, and I believe that helped us to set the proper expectations early on.  There have been a few customers that have needed our assistance on Fridays and we’ve been able to fill those needs by various team members volunteering to take care of those needs.  Each of our regular customers have cell phone numbers for members of the management team, and if something unforeseen comes up on Fridays, they can call and get help most of the time.  But the calls have slowed down as customers have gotten used to us being closed on Fridays and they tend to plan accordingly whenever possible.

One unexpected benefit that came about from the schedule change was an opportunity to improve our Just-in-Time (JIT) procurement process.  In the past we have ordered all parts at the start of a project, which led to them being assembled as they trickled in.  This method caused a number of inefficiencies for us: the assembly technicians wasted significant time starting a project and then stopping when they ran out of parts, we would have to pay for parts often before we really had any use for them, and there was often chaos created by people going through parts and then putting them back when they had to stop.  Sometimes parts would get put in the wrong totes or even on the wrong project rack.  With the new system we order parts as required, we do not accept early deliveries, and we ask all of our vendors to deliver parts on Thursdays.  On Fridays we have a part-time expeditor come in and receive parts and distribute them to their proper job kits.  When the assembly crew comes in on Mondays the parts are ready and waiting for them.

Overall, we’re very pleased with our 4-day work week experience and we plan on continuing with it into the foreseeable future.  If you have any thoughts about trying a four-day week at your company, my advice would be to embrace the concept and do whatever you can to make it work for you.  I know we have been pleasantly surprised by the positives!