Lean Automation
Lean automation is the standard practice on projects by Setpoint. When designing machines our engineers take into account that there will be defective parts that need to be rejected prior to the next test, inspection or assembly process. On the Micro-Gas Generator (MGG) machine, before a part is ever introduced into the machine it is checked for the right color, orientation, and size and is not allowed onto the machine if it is not correct. If during the process a part is found to be defective, the WIP (Work in Process) software will track the specific part and ensure the bad part is confined to a non compliant materials box. In the picture shown, a defective part tracked through WIP is deformed so that it can not be accidentally reintroduced into the system.
Lean Production
Using the Toyota Production System (TPS) philosophy, Setpoint produces turn-key solutions providing right-sized machines that fit into existing production areas. Quick change Single Minute Exchange of Dies (SMED) tooling is used to ensure each system is able to reach your economic order quantity. Through electrical and mechanical practices, Setpoint mistake proofs (pokayokes) each process to ensure correct tooling is installed the right way so that parts are processed correctly. An essential part of this process rejects bad parts from being passed through to the next assembly.
Lean Systems
Footprint is an essential element of lean, keeping the machines compact, simple and easy to work on is critical in the manufacturing process. Using lean systems Setpoint has designed work cells for production lines that have individual stations for each step in the process that can be re-tooled to incorporate a change in the part or process. With Single Minute Exchange of Dies (SMED) the tooling on each cell can quickly be changed over to process multiple parts within a family of products.
The image above is an overlay between a production line using linear technology in blue and the Setpoint line using lean automation in green. The lean system provided by Setpoint reduced the footprint by 83% from the original system. With the first Real Time Radiography (RTR) X-Ray Inspection project the customer had been using a process that took up an entire room. This non destructive inspection provided one of two tests that were done consecutively, the second test being an electrical test. When Setpoint finished designing and building the RTR the footprint was reduced to a width of 76” and depth of 65”. The x-ray inspection and electrical tests were incorporated into one machine to reduce handling frequency and cost.
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