Definition

• (6) Machines to drill aluminum: Chevy or Cadillac RH/LH parts (four different styles in total)
• Make the repurposed drill motors function
• Work without GDT
• The drill units automatically adjust side to side for either hand parts.
• The various models have varying part lengths.
• Change over between models: has to be less than 15 minutes.
• Part load to be vertical for minimal floor space.
• All the extrusions are formed (bent) resulting in inconsistency in geometry through the center axis.
• Material handling: cut off end pieces
• Find a means for a right hand part in the right hand nest without having to “baton” the part.

Implementation:

• Identify what had to be changed over and what had to move while maintaining tolerance
• Color code the four parts blue, yellow, red and green and carry that over to the machine function.

Results:

• Machine cycle time 4 seconds not including load/unload.
• Change over time of 3 seconds. The 15 minute requirement could not have been meant via manual changeover - this had to be automatic.
• Multiple parts can be run in one machine.
• Consistent and repeatable output by not having a manual changeover.
• Right hand part is loaded in the right hand nest without having to “baton” the long parts for correct orientation.
• Air blow off to move the cut off piece into the chute.
• Visible four color stack light on all six machines. One color on all six machines indicates run of one style part.
• Time improvements beating target time by: 73% for machine cycle.