MICRO-GAS GENERATOR (MGG) LINE
THE CHALLENGE
Setpoint’s customer needed a custom automated product line in a new facility that was currently being produced in another facility. One of the significant problems with the existing machine was the amount of floor space it required. The current machine would not fit into the new facility. The customer needed to reduce the size of the machine required to produce the product as well as increase throughput and reduce the per unit cost.
PRODUCTIVITY DELIVERED
Setpoint’s automation expertise coupled with robust planning, definition, and execution produced a machine that achieved the customer’s objectives. Setpoint’s custom machine delivered the following results:
- Increased throughput
- Decreased labor minutes per unit
- Significantly reduced required floor space
Mike Fielding of Rockwell Automation said, "it is the most I/O intensive machine in North America."
SUMMARY
Setpoint’s definition phase included an onsite visit to study the existing process. Setpoint then created a simulation model of the production line to better define the new system, identify potential constraints and interactions to understand potential problem areas before a detailed design effort was undertaken. This approach enabled the timing and process flow of each station to be better understood early in the process of working toward a successful solution.
Setpoint’s solution included leading edge technologies applied in innovative ways. A vision-guided Epson SCARA robot was integrated for product placement based on a multitude of criteria. This system enabled the identification and segregation of faulty components. Vision systems were used for part compliance and process validation, pyrotechnic weigh & fill systems were integrated as well as precision scales that verified pyrotechnic loading was accurate. Each of these stations had the capability of identifying faulty parts.
Overall, there were 39 simultaneous operations occurring within a 3 second cycle. In order to reduce the amount of wiring, Setpoint used Ethernet IP requiring far fewer control, diagnostic and communication lines than other protocols. This meant that less of everything was required to bring a sophisticated line to fruition.