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Presentation Virtual Plant Layout Halit Burak Nazir
- 1. DESIGNING A ROBOT CELL By Team F: Akshay Rajendra (00036061) Halit Burak Nazir (00037836) Srikanth Sritharan (00033335) Taha Javed (00033193)
- 2. Tasks and challenges • Production of one (small) size of the control cabinet • Annual amount of cabinets: 55,000 • 1-shift ONLY • 1 worker (the worker should be able to feed a second cell of the same type) • Use a handling robot and an external (stationary) weld gun and minimum one conveyor • 220 working days per year, 7.5 hrs. per day excluding 0.5 hr. break. • Total availability of workers plus robot cell: 80% • Left, right, bottom and top plate of the control cabinet should be spot- welded • The back plate, door and hook are added manually afterwards. Not included in our task.
- 3. Yearly Demand = 55,000 Daily Production =55,000 / 220 Units per Day = 250 Units / Day 7.5 Hours / Day with 80% availability. Available time, considering 220 day per year, working 7.5 Hours a day with 80% availability = (220)*(7.5)*(3600)*(0.8) = 4752000 Sec. Time Available for each cabinet comes out to be 86.4 Sec.(4752000/55,000 ) If we consider the time loss due to the faulty pieces in raw material or else, if try to produce 2% more than the desired amount so that we can reach our goal with comfort then: 4752000/(55,000 + 2% of 55000) = 84.7 sec. Available time
- 4. Choices for machinery • Use of turn tables or conveyor for material transport in and out of the cell? • Use of multiple Weld guns? • Use of multiple Robots? • Which Robot? • Standard safety features. Note : Stainless steel (2.5*2 + 6.5*2) kilos (parts) plus 10 – 15 kilos (fixture) = 30 - 35 kilos in total.
- 5. Our Approach Process Equipments • Two Conveyors for material transport. • One Robot(KR 100). • Single specially designed Weld gun. • Designed Fixtures. • Grooves to hold the input in precise positions (Increase in Scrap) • Conveyor position.
- 6. Simulation • Please click here for the simulation.
- 7. Gantt Diagram Reference : VPL_GroupF_GanttDiagram.xlsx Gantt Diagram contents in brief : • Gantt Diagram Robot Cell • Gantt Diagram Worker • Cycle Time Calculations
- 8. Customer Demand : Yearly Demand = 55,000 Daily Production = 55,000 / 220 = 250 Units per Day Rejection Rate = 2% Yearly Demand including Rejection = 1.02*55000 = 56100 Production Demand : Working Hours / Day = 7.5 Overall availability of robot + worker = 80% = 0.8 Working Days per Year = 220 Theoritical Production Cycle Time in seconds = (220*7.5*0.8*60*60) / 56100 = 84.71 Parts to be produced per Day = 56100 / 220 = 255
- 9. Work contributions per cycle Worker Idle Robot Key Results from Gantt Diagram: Robot Cycle Time = 68.2 seconds Worker Cycle Time = 73.5 seconds Overall Cycle Time = 73.5 seconds Worker Utilization Rate = 86.77 % Robot Utilization Rate = 80.51 % Working Hours per Day = 5.21 hours
- 10. Cost calculation • Please click here for access to cost calculation (Excel file)
- 11. Safety measures taken The design of the robot cell should be such that nobody could be hurt by movements of robot/machines or processes inside the cell. A decent balance between the investment in safety measures and the risk of injury. Simple, robust and reliable. • Fence ,to secure the area of operation • Light curtain above (sufficient height adjusted for the desired object) the conveyor belt. If any entity trespass through the curtain the machine stops working and the lamp turns on) • Light lamp, indicates any error or state.
- 12. Spending on safety measures 9% Safety expense Other costs
- 13. Questions? • Thank you for your attention