kaizen presentation - bonding detector
DESCRIPTION
Part of the Internship programme where I lead a team of engineers to find any improvements in the production line of Canon camera Assembly to reduce costTRANSCRIPT
waste eliminationUV Bond | Level Detector
ASSY. PRODUCTION ENGINEERINGAMIR ASYRAF BIN MOHAMMAD REDZUAN
13838
• UV Bonding Machine–Mushashi Shotmini 100s –
table top robot–Syringe tube
• 100cm3 capacity• High opacity – prevent
bond exposed to UV light
OVERVIEW• Bonding process
–Assemble L254 Focus Motor & Holder Sensor
–UV Bond qty per/pcs :
BONDING AREA
StartDispense
Curing
Inspection
End
BEFORE IMPROVEMENT
CONSEQUENCEUnnecessary frequent
refilling needed
PROBLEM• Operator has
difficulties to determine content level reach minimum level
Frequent refilling (40times/month)• Quality Problem – Part
not properly bonded
???
Too dependent on human judgment
due to syringe opacity
作業者にたよる目視判定（無駄な動き /時間）
BEFORE IMPROVEMENT
CONSEQUENCEUnnecessary frequent
refilling needed
after UV bond reach below minimum level, dispensing pressure inconsistent
(2) Concept of minimum levelafter UV bond reach below
minimum level, dispensing pressure inconsistent History-EC335 CCD UV bonding(Average 2times/mth)(gmbr) (countermeasure-frequent refilling)
Visual Inspectio
n
CuringPLUNGER
MAGNET
UV Bonding
OK
Sensor triggered?
END
Refill
YESNO
STARTDesign mistake proof system of early detection of UV Bonding level
AFTER IMPROVEMENT
SENSOR
AUTOMATICALLY STOP
When leveled with magnet - sensor triggered and relay will contact and send signal to emergency switch – operation stops
If magnet inside plunger not level with sensor – relay contact release
• Insert magnet in the plunger and install relay sensor
• At a certain level the sensor will detect the magnet when the plunger is at low level so it can be refilled
MAGNET INSERTED
IN THE PLUNGER
HOW WE DO IT
Before AfterFrequency of refilling
2 times/day= 40 times/month
1 time/ 2 days= 10 times/month
Cost time to refill(RM)
3minutes X 60s X 40times/month X 12months X RM0.08/part= 6912
3minutes X 60s X 10times/month X 12months X RM0.08/part= 1728
Cost no. of steps taken to refill(RM)
40steps X 40times/month X 12month X RM0.08/part= 1536
40steps X 10times/month X 12month X RM0.08/part= 384
TOTAL (RM) 8448 2112TOTAL SAVING = RM6336
ROI : 0 MONTH(
EFFECTIVENESS
• Expansion to all EF lenses models
ModelAugust September October
W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4
L254
L35
L240
L114/L116
L248
MC1 COMPLET
ED
FUTURE PLAN
MC2
MC2
MC2
MC2
MC2
THANK YOU AND HAPPY
INDEPENDENCE DAY