Continuous improvement of a machining process by designing a new jig
Autor(a) principal: | |
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Data de Publicação: | 2018 |
Tipo de documento: | Dissertação |
Idioma: | eng |
Título da fonte: | Repositório Científico de Acesso Aberto de Portugal (Repositórios Cientìficos) |
Texto Completo: | http://hdl.handle.net/10400.22/12709 |
Resumo: | This thesis report gives an insight on how an often overlooked, jig and fixture used as a manufacturing aid to produce a product and essential for delivering products reliably and repeatedly with high quality. This continuous improvement project of an exciting machining process of winding cones used overhead garage doors. The improvement was a necessity with a forecast for 2019 estimating the need for 43% faster production cycle (takt time) compared to the previous year. Hence, the main objective was to reduce the machining time required per part by designing a modular jig system, ideally with 12 parts per cycle. To make the work in an organized structure the project was dived into four phases namely: research, design, machining and implementation. The research phase included in the study of the old jig in use, analysing the process and sketching the basic requirements. The design phase was based on the methodology of Design for Six Sigma methodology for the fixture. Different kind of jig components was designed and assembled using SOLIDWORKS CAD model. The critical review of design iteration was analysed using SWO analysis (short version of the standard SWOT analysis) for design. The machining of most components of the jig was done in-house with tacit knowledge of the machinist instead of using CAM software’s making it first of its kind project in developing knowledge management in the company for future jig requirements. The critical outcomes of the project were harvested from the implementation phase. The newly machined modular jig system proved to have increased the number of parts machined per day by 32% with expected savings of more than €6000 per annum. The added benefit of a modular jig system was that one base (skeleton of the jig) could be used in machining different products. Also, future projects now have the intellectual and physical resources of making jigs and fixtures in-house. This drastically reduces the lead times for new parts, which is crucial for a small-medium enterprise stay competitive. |
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Continuous improvement of a machining process by designing a new jigJigs and fixturesSix Sigma for designContinuous improvementSOLIDWORKSGabaritos e acessóriosSix Sigma para designMelhoria contínuaGestão IndustrialThis thesis report gives an insight on how an often overlooked, jig and fixture used as a manufacturing aid to produce a product and essential for delivering products reliably and repeatedly with high quality. This continuous improvement project of an exciting machining process of winding cones used overhead garage doors. The improvement was a necessity with a forecast for 2019 estimating the need for 43% faster production cycle (takt time) compared to the previous year. Hence, the main objective was to reduce the machining time required per part by designing a modular jig system, ideally with 12 parts per cycle. To make the work in an organized structure the project was dived into four phases namely: research, design, machining and implementation. The research phase included in the study of the old jig in use, analysing the process and sketching the basic requirements. The design phase was based on the methodology of Design for Six Sigma methodology for the fixture. Different kind of jig components was designed and assembled using SOLIDWORKS CAD model. The critical review of design iteration was analysed using SWO analysis (short version of the standard SWOT analysis) for design. The machining of most components of the jig was done in-house with tacit knowledge of the machinist instead of using CAM software’s making it first of its kind project in developing knowledge management in the company for future jig requirements. The critical outcomes of the project were harvested from the implementation phase. The newly machined modular jig system proved to have increased the number of parts machined per day by 32% with expected savings of more than €6000 per annum. The added benefit of a modular jig system was that one base (skeleton of the jig) could be used in machining different products. Also, future projects now have the intellectual and physical resources of making jigs and fixtures in-house. This drastically reduces the lead times for new parts, which is crucial for a small-medium enterprise stay competitive.Este relatório dá uma visão sobre como um acessório usado pode auxiliar na produção de forma a produzir um produto e os elementos essenciais para a sua entrega de forma confiável e repetida com alta qualidade. Este é um projeto de melhoria contínua de um processo de maquinagem de cones de enrolamento, usados em portas de garagem suspensas. A melhoria surjiu de uma necessidade com a previsão para 2019, estimando a necessidade de um ciclo de produção 43% mais rápido (takt time) em comparação com o ano anterior. Assim, o objetivo principal passava por reduzir o tempo de maquinagem necessário por peça, projetando um sistema de gabarit modular, idealmente com 12 partes por ciclo. Para realizar o trabalho numa estrutura organizada, o projeto foi dividido em quatro fases: pesquisa, projeto, maquinagem e implementação. As fases de pesquisa foram incluídas no estudo do antigo gabarit em uso, analisando o processo e esboçando os requisitos básicos. A fase de projeto foi baseada na metodologia de Design for Six Sigma para um dispositivo. Foram projetados e montados diferentes tipos de componentes de gabarit usando o modelo SOLIDWORKS CAD. A revisão crítica da iteração do projeto foi analisada usando a análise SWO (versão reduzida da análise SWOT convencional) para projeto. A maquinagem da maioria dos componentes do gabarit foi feita internamente com conhecimento tácito do responsável técnico, recorrendo ao software CAM, tornando-o o primeiro de seu tipo no desenvolvimento da gestão do conhecimento na empresa para futuros requisitos de gabarit. Os principais resultados e conclusões dos projetos foram descritos na fase de implementação. O sistema de gabarit modular recém-maquinado provou ter aumentado o número de peças maquinadas por hora em 32%, com economias comprovadas de mais de € 6.000 por ano. O benefício adicional de um sistema de gabarit modular consiste de criar uma base (esqueleto do gabarit) usada na maquinagem de diferentes produtos, e projetos futuros, permitindo à empresa deter os recursos intelectuais e físicos de criar gabarits e acessórios internos. Assim, foi reduzido drasticamente o tempo de espera para novas peças, o que é crucial para uma pequena média empresa permanecer competitiva.Campilho, Raul Duarte Salgueiral GomesRepositório Científico do Instituto Politécnico do PortoKumar, Sampath2019-01-23T11:42:09Z20182018-01-01T00:00:00Zinfo:eu-repo/semantics/publishedVersioninfo:eu-repo/semantics/masterThesisapplication/pdfhttp://hdl.handle.net/10400.22/12709TID:202026663enginfo:eu-repo/semantics/openAccessreponame:Repositório Científico de Acesso Aberto de Portugal (Repositórios Cientìficos)instname:Agência para a Sociedade do Conhecimento (UMIC) - FCT - Sociedade da Informaçãoinstacron:RCAAP2023-03-13T12:54:42Zoai:recipp.ipp.pt:10400.22/12709Portal AgregadorONGhttps://www.rcaap.pt/oai/openaireopendoar:71602024-03-19T17:33:01.018373Repositório Científico de Acesso Aberto de Portugal (Repositórios Cientìficos) - Agência para a Sociedade do Conhecimento (UMIC) - FCT - Sociedade da Informaçãofalse |
dc.title.none.fl_str_mv |
Continuous improvement of a machining process by designing a new jig |
title |
Continuous improvement of a machining process by designing a new jig |
spellingShingle |
Continuous improvement of a machining process by designing a new jig Kumar, Sampath Jigs and fixtures Six Sigma for design Continuous improvement SOLIDWORKS Gabaritos e acessórios Six Sigma para design Melhoria contínua Gestão Industrial |
title_short |
Continuous improvement of a machining process by designing a new jig |
title_full |
Continuous improvement of a machining process by designing a new jig |
title_fullStr |
Continuous improvement of a machining process by designing a new jig |
title_full_unstemmed |
Continuous improvement of a machining process by designing a new jig |
title_sort |
Continuous improvement of a machining process by designing a new jig |
author |
Kumar, Sampath |
author_facet |
Kumar, Sampath |
author_role |
author |
dc.contributor.none.fl_str_mv |
Campilho, Raul Duarte Salgueiral Gomes Repositório Científico do Instituto Politécnico do Porto |
dc.contributor.author.fl_str_mv |
Kumar, Sampath |
dc.subject.por.fl_str_mv |
Jigs and fixtures Six Sigma for design Continuous improvement SOLIDWORKS Gabaritos e acessórios Six Sigma para design Melhoria contínua Gestão Industrial |
topic |
Jigs and fixtures Six Sigma for design Continuous improvement SOLIDWORKS Gabaritos e acessórios Six Sigma para design Melhoria contínua Gestão Industrial |
description |
This thesis report gives an insight on how an often overlooked, jig and fixture used as a manufacturing aid to produce a product and essential for delivering products reliably and repeatedly with high quality. This continuous improvement project of an exciting machining process of winding cones used overhead garage doors. The improvement was a necessity with a forecast for 2019 estimating the need for 43% faster production cycle (takt time) compared to the previous year. Hence, the main objective was to reduce the machining time required per part by designing a modular jig system, ideally with 12 parts per cycle. To make the work in an organized structure the project was dived into four phases namely: research, design, machining and implementation. The research phase included in the study of the old jig in use, analysing the process and sketching the basic requirements. The design phase was based on the methodology of Design for Six Sigma methodology for the fixture. Different kind of jig components was designed and assembled using SOLIDWORKS CAD model. The critical review of design iteration was analysed using SWO analysis (short version of the standard SWOT analysis) for design. The machining of most components of the jig was done in-house with tacit knowledge of the machinist instead of using CAM software’s making it first of its kind project in developing knowledge management in the company for future jig requirements. The critical outcomes of the project were harvested from the implementation phase. The newly machined modular jig system proved to have increased the number of parts machined per day by 32% with expected savings of more than €6000 per annum. The added benefit of a modular jig system was that one base (skeleton of the jig) could be used in machining different products. Also, future projects now have the intellectual and physical resources of making jigs and fixtures in-house. This drastically reduces the lead times for new parts, which is crucial for a small-medium enterprise stay competitive. |
publishDate |
2018 |
dc.date.none.fl_str_mv |
2018 2018-01-01T00:00:00Z 2019-01-23T11:42:09Z |
dc.type.status.fl_str_mv |
info:eu-repo/semantics/publishedVersion |
dc.type.driver.fl_str_mv |
info:eu-repo/semantics/masterThesis |
format |
masterThesis |
status_str |
publishedVersion |
dc.identifier.uri.fl_str_mv |
http://hdl.handle.net/10400.22/12709 TID:202026663 |
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http://hdl.handle.net/10400.22/12709 |
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TID:202026663 |
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eng |
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eng |
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info:eu-repo/semantics/openAccess |
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openAccess |
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application/pdf |
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Repositório Científico de Acesso Aberto de Portugal (Repositórios Cientìficos) - Agência para a Sociedade do Conhecimento (UMIC) - FCT - Sociedade da Informação |
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