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August 6, 2020
We would like to share with you this Application Improvement Example.
   Application Example   

Defective Product Screening Equipment

Equipment Overview

  • Packs filled with shampoo are transferred in the X direction on a conveyor.
  • The weight of the shampoo packs are measured by a weight checker when they are transferred onto the conveyor.
  • If the weight is outside the allowable range, air cylinder Ⓐ stops the pack and air cylinder Ⓑ discharges it to the Y direction as a defective product.

   Before Improvement

  Problems  

Defective products sometimes got past the rejection process due to the slow movement of air cylinder Ⓐ that was caused by fluctuation of the source air pressure.
➨ When the movement is too slow, an alarm activates and a choco-tei (a temporary stop) occurs.

Likewise, before Air cylinder Ⓑ discharged a defect, a new shampoo pack was often fed on the weight checker conveyor, which disabled a weight measurement.
➨ When the measurement failed, an alarm activated and choco-tei (a temporary stop) occurred. Also, some defective products did not fall in the defective product box, but fell out of the box.

Choco-tei (a temporary stop) due to Air cylinders Ⓐ and Ⓑ took place an average 3 times a day, each of which took 10 minutes of adjustments for recovery.

It took a total of 30 minutes per day for recovery from the choco-tei (temporary stop).
 

»  3 times x 10 minutes = 30 minutes/day

   After Improvement

  Improvement by Motorization  

✪ Air cylinders Ⓐ and Ⓑ have been replaced by ELECYLINDERs.

✪ The result of the introduction of ELECYLINDERs is as follows:

Ⓐ Thanks to no speed fluctuations, defective products are not getting passed the rejection process.
The alarm no longer activates and choco-tei never occurs.

Ⓑ Because there are no speed fluctuations, another shampoo pack is no longer fed onto the weight checker conveyor before the proper time.
The alarm is not activated and choco-tei no longer occurs.

Defective products do not fall out of the reject box.

✪ No choco-tei occurs and no time is spent for recovery.
 

»  Time for recovery: 0 minute / day

  Effects     (Condition: Labor cost US$12/hr, Annual operation 240 days.)

✪ Working hours has been reduced by 30 minutes per day.
      Recovery time of 30 minutes per day from choco-tei has been eliminated.

✪ Annual saving for labor cost is US $1,400.
      US$12 x 30 minutes (10 min. x 3 times) x 240 days = US$1,440.
      *Exchange Rate: 1 (USD) = 100 (Japanese Yen).

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