PolyWorks Conference USA 2014 •Personal Biography – Education: I.T.T. Technical Institute – Quality Assurance - Metrology Planner •Kalida Manufacturing Inc. (KMI) – – – – Subsidiary of KTH Parts IND. Established in 1996 Tier 2 Honda Motors Supplier Produce stamped and welded frame subcomponents for every Honda automobile produced in North America. PolyWorks Conference USA 2014 INTRODUCTION: Background: • Before March 2011 – Measured with taper scales – Measurements recorded by hand and stored in file cabinet PolyWorks Conference USA 2014 • March 2011 - Present – Current Measuring Technique • • • • Data Recorded Electronically PCMM Touch probe Laser scanning DATA COLLECTION HISTORY: Stamping Data Collection •Statement of Purpose – To develop a system of processes that are simple to use, increase data collection productivity, shows time savings, and are compatible with all of KMI’s PCMMs (Faro, Romer). •System of PolyWorks Application Tools – Data evaluation: SPC abnormal condition, tolerances range color coding – Fixture layout, jig layout: gage R&R – Program development: creation, editing – Data collection: scanning, probing •Benefits PolyWorks Conference USA 2014 – – – – Efficiency Quality Time and Cost Savings ROI Analysis PRESENTATION OVERVIEW: Lean Process Improvement PolyWorks Conference USA 2014 Challenge: • Use • Efficiency – Probe data collection guided images • Purpose – Collection of images used to assist data collectors to identify the location of each single feature or comparison point. • Result – Supports novice operators and increases data collection speed PolyWorks Conference USA 2014 – Creation time is long • Locating in 3D scene • Separate and hide Features/Comparison pts. • Rename snapshots • Exporting images to external source • Image Quality – Zoomed too far in or out – Varying view perspectives – Inconsistent OVERVIEW: Process: Locate Object Adjust 3D Scene Zoom In or Out Initiate Snapshot OPERATOR YES Rename Snapshots Gather 3D Image Verify Images Anymore Objects? NO Export Snapshots POLYWORKS Place in Report Items PolyWorks Conference USA 2014 Process Time: @ 30 Minutes END CHALLENGE PROCESS FLOW: START OPERATOR Initiate Snapshot Macro Process Time: @ 1 Minutes END Set Primary View Verify Images YES POLYWORKS Locate Object Adjust 3D Scene Build View Checks Initiate Snapshot Gather 3D Image Place in Report Items PolyWorks Conference USA 2014 Is Object Blocked? Rename Snapshots NO Zoom to set depth Anymore Objects? YES Move Snapshots NO SOLUTION PROCESS FLOW: START DEMONSTRATION: PolyWorks Conference USA 2014 •Time – 29 minutes Saved – Breakeven Point • 166 programs (Currently 702 programs) •Multitasking Quality •Images – Consistent Perspectives •Location – Images stored in the same location Continuing Benefits – Time Savings: 207 hours per year PolyWorks Conference USA 2014 BENEFITS: Efficiency PolyWorks Conference USA 2014 Challenge: • Use • Efficiency – Scan data reports • Purpose – Hard copy reports that show alignments, part condition, and potential part fit for every time a part is scanned. (@ 5 scans daily) • Result – Assist suppliers, customers, management, and maintenance to understand part condition. PolyWorks Conference USA 2014 – Creation time is long – Manual snapshots and reporting – Manual input part information • Report Quality – Missing report sections – Snapshots inconsistent OVERVIEW: Process: OPERATOR Check Report Gather Snapshots Missing Items? Select Report Items Create Tables NO Fill in Report Info Generate Generic Report Export Report YES Correct Report Items POLYWORKS Fill in Report PolyWorks Conference USA 2014 Email or Store Report END Process Time: 6 Minutes CHALLENGE PROCESS FLOW: START Adjust 3D Scene OPERATOR Initiate Reporting Macro Process Time: 1 minute END Set Primary View Verify Report POLYWORKS Initiate Section Pic. Macro Generate Cover Image Export Report Store Report PolyWorks Conference USA 2014 Generate Alignment Info Generate Structured Report Fill Report in Correct Areas Fill in Report Info SOLUTION PROCESS FLOW: START DEMONSTRATION: PolyWorks Conference USA 2014 •Time – 5 minutes saved for scan report • Time Break-even point 480 new scan programs or 96 working days •Multitasking Quality •Report – Ensured part information existence – Consistency – Exclusive Style Continuing Benefits – New associate to macro writing < 5 months PolyWorks Conference USA 2014 BENEFITS: Efficiency PolyWorks Conference USA 2014 • Varying data – How hard does operator push scale in? – How does the operator read the scale? PolyWorks Conference USA 2014 Recorded by Hand and Stored in File Cabinet • Deficiencies – Slow (Operator Records) – Inefficient storage (File Cabinet) – Slow Communication Case Study Time: 35 minutes PREVIOUS METHOD: Measured with Taper Scale •Programs – Cloned programs – Linked data trend chart •Program Directory – Easy method for program discovery •Touch Probe – Fluent data collection – Consistent readings Case Study Time: 15 minutes PolyWorks Conference USA 2014 CURRENT SOLUTION METHOD: KMI PolyWorks Tool Manager DEMONSTRATION: PolyWorks Conference USA 2014 •PolyWorks – Measurements recorded as taken – Data stored electronically on servers – Data accessible immediate Quality •Data – Touch Probe • Ensures constant force – Consistency Occurring Benefits – Ease of use • • Provides simplified processes Minimum training required PolyWorks Conference USA 2014 BENEFITS: Efficiency • Efficiency – Guided images – Short training time frame • Time and Cost Savings – Electronically stored data – Quickened process – Continuous improvement activities • Quality – Consistent data collection – Scan reports KMI’S Future Process Improvement • KMI PolyWorks Tool Manager – Data Collection Process • Target Time: < 6 minutes • Addition of new measurements without increasing time • Data link between cloned programs – External Data Hub – Automated Program creation • Auto program update • Simplified program editing – Program change tracking – One Time Alignment • Multi-part fixtures PolyWorks Conference USA 2014 CONCLUSION: Macro Scripting for Lean Process Improvement PolyWorks Conference USA 2014
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