Last time we introduced a method to express setup & adjustment loss with tooling activities.
This time we introduce one method to reduce the influence of loss due to this setup procedure.
*Since we will proceed with the explanation based on the project created by Tech Magazine last time, please make it with reference to the following URL if it is not created yet.
The 7the: Let's express the loss! ~ Howe to use the Tooling Activity ~
In general, it is clear that parallel processing with multiple equipment is more productive than when one processing is done with one piece of equipment.
However, this assumes the case of producing one type of product, so it may not be the right example in the case of multi-product production.
Here, we examine the influence of setup in parallel machining of multiple equipment and see how much improving effect is by changing a flowing method.
The prerequisites of the manufacturing process discussed last time were as follows.
# Manufacturing process of each product
Product A: press processing A1 (30 seconds) --> press working A2 (20 seconds)
Product B: press processing B1 (50 seconds) --> press processing B2 (40 seconds)
# Time required for mold change implemented at product replacing time
Installation: 15 minutes
Removal: 10 minutes
This time, we add the following conditions to this manufacturing process.
# Increase the equipment that performs press processing A2 and press processing B2 to two (facility 2-1 and facility 2-2).
# Even in the facility 2-1 and facility 2-2, replace the mold (clamping mold) at the time of product replacement.
Installation: 30 minutes
Removal: 20 minutes
1. Change the floor plan and its linkage
Add one facility to the floor plan and make it easy to distinguish.
Here, the last "facility 2" is set to "facility 2-1", and the added facility is to be "facility 2-2".
Also, in order to process the press processing A2 and the press processing B2 in parallel with "facility 2-1" and "facility 2-2", we link between two as follows.
2. Add a tooling resource
Add clamping mold A and clamping mold B to the tooling master.
3. Add a tooling activity
For facility 2-1 and facility 2-2, add tooling activities for each press processing.
4. Confirmation of simulation execution result
As for the production plan, we target 50 pieces at the same time as the last time. After performing the production rendering with the input order "10 products A --> 10 products B --> …", watch the Production Cockpit and the material flowchart. Then, you can see that there is equipment stoppage due to the setup in equipment 2-1, equipment 2-2 respectively.
5. Improvement of flowing method
Up to now, we have produced products A and B with the facilities 2-1 and 2-2.
As a result, it was turned out that a stoppage due to setup at product replacement occurred in both facilities.
Let's change it to the following flowing method here.
-Production of product A is done from equipment 1 --> equipment 2-1. (Press processing A2 is implemented only in facility 2-1)
-Production of product B is done from equipment 1 --> equipment 2-2. (Press processing B2 is implemented only in facility 2-2).
The linkage explanation is as follows.
* After dragging and dropping to the equipment 2-2 while pressing the [A] key in press processing A2 and the linkage can be released. By performing the same operation from the press processing B2 to the facility 2-1, the association can be changed as described above.
6. Confirmation of improvement result
When production rendering is executed and Production Cockpit and material flow chart are confirmed, product replacement does not occur in facility 2-1 and facility 2-2, so that the facility stops the procedure by first one only, and you can find that the production capacity has been improved.
In this way, by grasping the facility stoppage due to the setup procedure by simulation, it enables to consider how to shed in consideration of the loss of product replacement that occurs when performing multi-product production.
This time, we introduced the examples of simple manufacturing flow, mold type, production order, and besides it is possible to verify with similar setting even more complicated condition.
Please use it by all means.
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