Interim Project Presentation
Improving Overall Equipment Efficiency in
Robotic Welding Cell
Mahesh L Malagavi
BUB0408017, PT08
M. Sc. (Engg.) in Engineering and Manufacturing Management
Proposed Academic Guide : Industrial Guide :
Asst. Prof. Sandeep N Mr. Mallikarjun GN
MSRSAS Engineer Electrical R & D
M.S.Ramaiah School of Advanced Studies 1
Aim of the Project
Improving the OEE of Robotic welding cell by 20%, applying lean
techniques
M.S.Ramaiah School of Advanced Studies 2
Project Objectives
• To review the literature on OEE, lean methodology and robotics
in welding to enhance the productivity
• To study and analyse the present welding practice, robotic
welding cell operations
• To evolve at the right strategy to improve OEE of robotic welding
cell
• To develop work cell model and simulate for quantifying the
improvements
• To implement and validate the recommended solutions in the
robotic welding cell
M.S.Ramaiah School of Advanced Studies 3
Methods and Methodology
• Literature review on the role of OEE in enhancing productivity in
robotic welding cell by referring to journals, books, manuals and related
documents
• Detailed study on each activity of robotic welding cell will be carried
out using QC tools
• Lean techniques such as SMED, Poke-yoke and Jidoka (Autonomation)
will be explored for improving OEE.
• Appropriate solution will be selected using prioritization matrix, AHP,
etc
• The selected solution will be verified through Roboguide simulation tool
to ensure improvements and safety factors
• Implementing the solution through tools like KAIZEN board on pilot basis
• SOP will be formulated for sustaining the improvement in the robotic
welding cell
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Place of work
M. S. Ramaiah School of Advanced Studies
#470-P, Peenya Industrial Area, 4th Phase
Peenya, Bangalore – 560 058
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Literature Review
• According to Taina Savolainen[1] Continuous improvement (CI) is defined
as “an organization-wide process of focused and sustained incremental
innovation”
•According to Danny J. Johnson[2] - Manufacturing throughput time
reduction can often be a daunting and confusing task due to the large number
of factors that can be changed and the interactions between them. The basic
factors are setup time, process time, batch transfer time, waiting time.
Manufacturing plants striving to reduce throughput time must decide where to
focus their efforts
• According Claire Moxham and Richard Greatbanks[3] says that the
effective implementation of SMED needs a number of fundamental
requirements called as prerequisites. Adoption and implementation of these
fundamental requirements will be classified as SMED-ZERO
M.S.Ramaiah School of Advanced Studies
Summary of Literature Review
Lean is aimed at reducing waste and adding value to production
systems so that systems performance is significantly improved and a
company “does more with less”
Reduction in throughput time is reduction in set up time, process
time, batch transfer time and waiting time.
Introducing prerequisites called as SMED ZERO is an essential
activity for successful implementation of SMED.
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Flow chart - present operation in robotic welding cell
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Present time study
operation Robot Operator
Sl. No Description
Time (in min) idle time idle time
1 Arrange work tools 15 15
2 Fixture set up 20 20
3 Robot power on 3 3
4 Search program 3 3
5 Load Raw Material 5 5
6 Put emergency 1 1
7 Unload and load the raw material 7 7
8 Release EMG and cycle start 1 1
9 Wait for cycle end (Actual weld time) 8 8
10 Cycle repeats from step 7
M.S.Ramaiah School of Advanced Studies
9
Present time study
22
20
18
16
14
Axis Title
12
10
0
Release Wait for
Unload
Arrange Robot Load Put EMG cycle
Fixture Search and load
work power Raw emergen and end(Actu
set up program the raw
tools on Material cy cycle al weld
material
start time)
1 2 3 4 5 6 7 8 9
operation Time (in min) 15 20 3 3 5 1 7 1 8
Robot idle time 15 20 3 5 1 7 1
Operator idle time 3 8
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Observations on Time Study
Fixture set time reduction
Reduce non-value adding robot movements (Repositioning points)
Operator movements
First cycle check
Visual inspection of welded parts
Unload and load raw material
Operator waits for cycle end
Robot waits for unload and loading of parts
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Ideas to be implemented
ACTION FOR
Sl. no PRESENT PROPOSED Status
IMPROVEMENT
Visual management completed
Fixture setup time Fixture and program
1
reduction identification Standardize In-progress
Welding path to be re-
In-progress
Avoid non-value adding teach
2 Refine program
robot movements
Reprogramming In-progress
Operator movements Mobile tool kit
3 Easy accessibility of tools completed
Twin pallet system for
Robot and operator
4 better utilisation of the SMED In-progress
waiting time
resource
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Visual management
Fixture without identification Fixture with identification
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Weld time and load/unload time
Base Load/unload
Material OpAc Work ctr Operation short text UoM Setup Un Weld Time M/c Un
Quantity Time
00103P0074 2010 SMDROB02 ROBO WELDING 1 EA 7 MIN 6 MIN
00103P0077 2010 SMDROB02 ROBO WELDING 1 EA 2 MIN 5 MIN
00103P0082 2010 SMDROB02 ROBO WELDING 1 EA 2 MIN 6 MIN
00103P0211 2010 SMDROB02 ROBO WELDING 1 EA 3 MIN 6 MIN
00103P0217 2010 SMDROB02 ROBO WELDING 1 EA 2 MIN 4 MIN
00103P0790 2010 SMDROB02 ROBO WELDING 1 EA 3 MIN 4 MIN
00103P0800 2010 SMDROB02 ROBO WELDING 1 EA 7 MIN 15 MIN
00105P0019 2010 SMDROB02 ROBO WELDING 1 EA 3 MIN 4 MIN
03108P0043 2010 SMDROB02 ROBO WELDING 1 EA 4 MIN 8 MIN
03108P0119 2010 SMDROB02 ROBO WELDING 1 EA 4 MIN 4 MIN
03108P0165 2010 SMDROB02 ROBO WELDING 1 EA 3 MIN 6 MIN
03108P0166 2010 SMDROB02 ROBO WELDING 1 EA 3 MIN 4 MIN
05105P0293 2010 SMDROB02 ROBO WELDING 1 EA 4 MIN 15 MIN
05105P0294 2010 SMDROB02 ROBO WELDING 1 EA 6 MIN 17 MIN
06106P0015 2010 SMDROB02 ROBO WELDING 1 EA 2 MIN 5 MIN
06106P0016 2010 SMDROB02 ROBO WELDING 1 EA 2 MIN 8 MIN
06106P0017 2010 SMDROB02 ROBO WELDING 1 EA 4 MIN 4 MIN
06106P0019 2010 SMDROB02 ROBO WELDING 1 EA 2 MIN 5 MIN
06106P0020 2010 SMDROB02 ROBO WELDING 1 EA 4 MIN 4 MIN
06106P0021 2010 SMDROB02 ROBO WELDING 1 EA 2 MIN 8 MIN
06106P0023 2010 SMDROB02 ROBO WELDING 1 EA 4 MIN 5 MIN
06106P0032 2010 SMDROB02 ROBO WELDING 1 EA 2 MIN 5 MIN
06106P0033 2010 SMDROB02 ROBO WELDING 1 EA 3 MIN 5 MIN
08103P0011 2010 SMDROB02 ROBO WELDING 1 EA 4 MIN 20 MIN
96104P0072 2010 SMDROB02 ROBO WELDING 1 EA 3 MIN 8 MIN
96104P0075 2010 SMDROB02 ROBO WELDING 1 EA 6 MIN 15 MIN
99103P0086 2010 SMDROB02 ROBO WELDING 1 EA 5 MIN 15 MIN
99110P0012 2010 SMDROB02 ROBO WELDING 1 EA 3 MIN 8 MIN
99110P0020 2010 SMDROB02 ROBO WELDING 1 EA 4 MIN 8 MIN
99110P0018 2010 SMDROB02 ROBO WELDING 1 EA 5 MIN 5 MIN
00103P0807 2010 SMDROB02 ROBO WELDING 1 EA 2 MIN 4 MIN
00103P0221 2010 SMDROB02 ROBO WELDING 1 EA 2 MIN 5 MIN
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Resources
Computing Resources:
• PC with 1 GB RAM, Pentium 4 processor
Software Resources:
• Microsoft Office
• 7 MP tools
Literature resources
• Books & Journals
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Liaterature
Journal Papers
[1]. Taina Savolainen., and Arto Haikonen, “Dynamics of organizational learning
and continuous improvement in six sigma implementation”(2007), The TQM
Magazine,Vol. 19, No. 1, pp. 6-17
[2]. Danny J. Johnson, A Framework for Reducing Manufacturing Throughput Time,
Journal of Manufacturing Systems, Volume:22, Issue 4, 2003
[3] Claire Moxham and Richard Greatbanks, Prerequisites for the implementation of
the SMED methodology, International Journal of Quality & Reliability
Management, Vol. 18, No. 4, 2001, pp. 404-414
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Benefits of the work
• Will it result into a publication? Yes
• Will it result into a product? No
• Will it be a solution to an existing problem of an industry?
Yes
• Is it pursued for academic interest? Yes
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Thank You
M.S.Ramaiah School of Advanced Studies 18
