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Master Presentation
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- 2. About myself • Bachelorof Electrical Engineering in McMaster University • Finished 3rd year of Electrical Engineering • Moved to Canada four years ago from Saudi Arabia
- 3. Daily Tasks Project management •Supervising, coordinating and providing technical support for installation Creating and updating electrical drawings PLC programming • Troubleshooting, editing and testing Monthly duties • Sealer and stud gun parameter sheets • PDCA electrical usage reports
- 4. Minor Projects • Gunpress valve replacements • Cycle Time • Point of Use • LubeCon Systems • WBS auto-greaser • Body shop energy usage 2015 (setting target) • PM&C performance screen • Dock 76 Aisle way lighting (High bay) • Updating Panel View Screen (HMI) • WB A/L’s Desk Alarm (D/L notifications) • Electrical Free issue re-organization • Obsolete Allen-Bradley contactor replacement • Lock-out tags • Bus plug accessibility audit • Torque and Angle-WB Stanley Guns (West & East) • Robot Pulse Coder Battery change (West & East) • Grease sampling • Sealer and Emhart Parameter Sheet updates • SSF torque auditing • Pliz Safety Relay swap out campaign • Servo motor fan replacements • WB LED lights-Up to GM spec. • Black& Mac Main panel AC unit cleaning program • Robot controller cleaning • PDCA upgrade • Downtime Reporting • Weld timer disconnect upgrades • Weld timer contactor replacements • Sodium high pressure lighting (high bay) • TIPs (establishing structure and executing project) • WBS crossover logic • Weld timer stepper verification • West Dash DeviceNet fix • HMI-Clamp 7-6 SBR Fix • WB Stand Alone uptime • Welding Tool calibration • Engineering & Maintenance Data organization • Stanley tool controller (missing bolts) • Turck armor block modules set-up procedure (for robots)
- 5. Major Project 1 WeldTimer Disconnects Problem • Toggle mechanism of disconnect cracking due to poor design • Weld timers cycle-powered by maintenance to troubleshoot resulting in broken disconnects • Bus plugs throughout Weld shop not accessible therefore shutting off the bus required
- 6. Major Project 1 WeldTimer Disconnects Solution • Alternative breaker • Audit bus plug accessibility • Audit number of cracking disconnects and prioritize • Shut down West and East side Red bus and coordinate upgrade
- 7. Major Project 1 WeldTimer Disconnects Results • All high and medium priority disconnects upgraded • Project completion=100% Funded through Contingency • A total of 80 cracked Weld timer disconnects upgraded • 80*4=320 hours of cumulative potential downtime avoided
- 8. Major Project 2 ThroughputTracking Stand Alone Uptime: Time in production-downtime Time in production-Throughput downtime
- 9. Learning experiences fromthis Internship • Management skills • Technical skills • ‘Real-world’ experience Thank you for this opportunity!
Editor's Notes
- #6 Problem: Weld timer disconnect toggle mechanism were cracking shop-wide due to poor design. When the weld timer was cycle-powered by maintenance to troubleshoot, the disconnect would break. In order to replace a disconnect the bus plug providing power to the weld timer must be shut off. In body shop over 50 bus plugs are not accessible, which meant we would have to shut down the bus in order to change out a disconnect.
- #7 The following was done in order to solve the problem: 1-A breaker with similar electrical and mechanical specifications was found (in order to minimize alterations made to the weld timer) with a better handle mechanism. 2-Conducted an audit of the body shop to determine accessibility of each bus plug. 3-Conducted an audit of every weld timer to determine how many are cracking, prioritized cracking disconnects into 3 categories. High=bus plug not accessible, medium= accessible on mezzanine level and low=bus plug accessible. 4-Shut down east and west red bus and coordinate project with over 20 electricians (3 shifts).
- #8 All high and medium priority cracking weld timer disconnects were upgraded. 100% project completion, project funded through contingency and funds fully used. 80 weld timer disconnects upgraded. 80*4= 320 hours of potential downtime avoided
- #9 Throughput Tracking: -Stand alone uptime is the uptime of the line, not accounting for the line being starved or blocked. Therefore just the performance of the line. -Production ALs track SA uptime daily -East and West stand alone uptimes being recorded were incorrect, worked with all 3 shifts, categorized faults into different categories and PLC changes were made to correctly display SA uptime (worked with IT). (display current formula used for SA uptime). -Main PM&C screen and performance screen was updated to reflect this change.