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Modification of Pick & Place Cam Part in SDKZ

Semi Auto Machine


Student: Muhamad Azrul Azim Bin Ramli
2013860692
Supervisor : Dr Kausalyah A/P Venkatason
Second Examiner: Dr Noor Azlina Binti Mohd Salleh

ABSTRACT

This project investigated the effectiveness and efficiency of the machine after had been upgrade from manual to semi
auto part. The experimental studies were conducted on studying the process of two machine which is SDKZ and RD
708 machine. In this project, the machine will be explained very detail how it can operate and works. Even SDKZ is
categorized in semi auto machine; there are still some parts that operate manually. It will cause the operation time of
the manual part is taking shorter than the semi auto machine. So, each process of the machine will be investigated to
make sure that the machine can reduce its operation time. By studying the process, the problem is caused by the pick
and place of cam in the machine is manually operated. Besides that, the productivity of the SDKZ product need to be
increased is one of the objectives in this project work. So, by study the concept of pick and place from RD 708
machine, the process and design of RD708 will be applied to the SDKZ machine. The process of process, assemble,
electrical and programming will be discussed in this project. From 2D CAD, it will be generated to the 3D model.
After the design has finished, it will modified so it can assemble to the SDKZ machine. Furthermore, the
manufacturing calculation was applied to the machine to make sure that the machine will be more effective and more
efficient.

Keywords: Machine, productivity, efficient and design.

1.0. INTRODUCTION

1.1. Background of Study


Nowadays, it is known as 21st century and also known as the world of new machine and technologies. In the
manufacturing industry, the most important process is material handling and assembly process. Manufacturing world
today is rising due to the development of technology; especially when the engineer becomes more creative in terms of
designing or innovating a new machine. The term of machine may allude to the mechanical generation, in which a few
segments are collected to frame the new item. Current product assembly machine are reliable enough to make
fabrication processes easier to move, orient, grasp and the component insertion.
The assembly machine is one of the most crucial systems to replace the manual line in the factory and it
gives more advantages. ALPS Electric (Malaysia) sdn bhd is a worldwide company that produces sensor, tact switch,
and potentiometer and mechatronic products. This company is one of the few in the industry that use machine either
manual or semi auto line. ALPS Electric for Malaysia located in Nilai as a head quarter. A mechanism is an
arrangement of machine components or segments or parts organized in a particular request to deliver a predefined
movement. The machine components or parts are viewed as inflexible or safe bodies which don't distort under the
activity of strengths. Some machine had been improved by the experienced engineer from the manual jig to the semi
auto machine.
The machine that uses to assemble the component is called automation machine. When using a semi auto
machine, there is some common problem happen during running. So process engineer need to study the process and
how to solve the problem. Therefore, it is essential to make sure the remanufacturing characteristics during the phase
of product design, to facilitate product reuse, improvements and maintenance, and to make sure it easier to
disassemble and recover. On top of that, they need to do some improvement on the machine called ‘Kaizen’. In this
case, design of the machine plays the important role. The ability to design requires both science and art. It is because
machine design can lead to the formation of the entirely new machine or it can lead to up-gradation or improvement of
the existing machine.
The objective of this study is to study and investigate the assembly process of pick and place (pnp) cam and
design of SDKZ machine and RD 708 machine. Besides that, the productivity of the SDKZ product need to be
increased is one of the objectives in this project work. In this study, we will be able or study the efficiency of manual
and semi auto machine in production of SDKZ switch.

1.2. Problem Statement


In the assembly product, the major problem that may happen is the quantity of productivity. The employer has their
own target for their product per month. During the process of assembly of the SDKZ switch product, the time taken by
the semi auto is too long which is 13s per cycle while the manual line is around 8s. This problem mainly caused by
the cam pick and place (pnp) process. The process happens after the inspection of contact blade and before the cam
grease. The process is totally manual made from Japan. This situation occurred during the cam is finish in the tunnel
and need to filled up by operator. So, the process needs to be stopped and affect the numbers of productivity of the
switch. However, after the research had been done, the process can be solved by upgrade the jig from manual to the
semi auto machine. Moreover, the cycle time can be decreased. Thus the target of productivity can be achieved.

2.0. LITERATURE REVIEW

Automation machine is the utilization of different control frameworks for working hardware, for example, apparatus,
forms in industrial facilities, boilers and warmth treating broilers, exchanging on phone systems, controlling and
adjustment of boats, air ship and different applications with insignificant or diminished human intercession. Factory
automation will focus on the product lines through electronic controls, fluid power and sensor products. The
automation machine use PLC as a cpu which is connecting the input and output of the machine. Since most recent
commercial PLC is use general purpose processors, they should execute an relay ladder logic (RLL) program.

2.1. Automation Machine


Automation machine are worldwide used in a manufacturing industrial. It is because this kind of machine has more
advantages than other types of machine. Such tasks require the companies to be able to counter too unpredictable,
rapid and fluctuating market changes in a responsive and cost -effective way. When industrial use automation
machine, there are produce higher turnout and productivity. Compared with manual machine, they use a lot of
workman thus affect the spent of salary to the workers. Automation machine has ability to operate 24/7. In this
evolving scenario, the industries that are able to minimize the expansion costs can obtain an advantage over the
challengers.
There are numerous convincing monetary preferences to running constant, every minute of every day
operations, including: expanded usage of capital speculation, changes in client administration, and diminished pay-
back time for interests in computerization. Including another undertaking in the sequential construction system
requires preparing with a human administrator; in any case, robots can be customized to do any errand. This makes
assembling process more adaptable. Simple machines is a term that most people think that they know about because
there are many machines that can be identified as simple all around us.

2.2. SDKZ Machine


SDKZ machine was developed to assemble a switch called SDKZ switch. This kind of switch is worldwide used for
home appliance. The example of home appliance that uses this switch is washing machine. One of the industrial that
conduct this machine is ALPS Malaysia sdn bhd. They have about 7 lines which is manual in operation. This machine
has 22 processes to assemble one product. There are few ways how along the product to be assemble one product. It
includes camera checking, pick and place, grease place and blow. This project will focus on the improvement on the
SDKZ machine.

2.3. RD 708
RD 708 was a machine that assembly a sensor called potentiometer. This kind of machine was made by Japan and also
imported from that country. RD 708 is semi auto type of machine. Based on the research, there are few process that
almost same with the SDKZ machine. The process is happen during the flow of cam through the channel.

2.4. Pick and Place Process


A process engineer manufacturer needed a solution for quiet, fast-paced pick-and place automation on their recently
designed sample transporting system. After they have done a research, they have found that pick and place process is
the best way to apply in the industry. Pick and place automation systems are frequently a portion of a bigger
mechanized gathering framework. Picking and placing is one of the greatest mutual tasks that a robot is required to
complete.
However, it is often hard for a robot to automatically plan its pick - and- place motion. One cause for this
difficult is the geometrical complexity of both the situation and the grasped item. [7] These machines are used in the
consumer goods industry for a wide variety of product transmission applications. ‘Part feeding & material transfer’ is a
key link in any chain of creation that can large affect work and the time variable of an assembling procedure.

3.0. METHODOLOGY

3.1. Introduction
In this creating time, to do such an examination of the computerization machine model is very less demanding and
does not require much time in light of the fact that everything should be possible for all intents and purposes by
utilizing programming. Thus, it is essential to form a simulation model in order to study and optimize the automation
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machine model. The core focus in this study is to improve the pick and place section in the SDKZ machine used at
industrial. This chapter will focus on the entire standard operation procedure (SOP) from the start until the
achievement of this study. Methodology is the regular study of procedures and particular way or set of procedures.

3.2. Flow Chart of Project Work


This project work has divided into two major process which is simulation work (at the top side) and experimental
work (at the bottom side). In the simulation work, the flow of project work has started with identifying the problem of
the machine. The literature review is by doing some research by process engineer and discussion with supervisor. The
input parameter of the machine needed to be implemented in the modification process. Study of both of the machine
was conducted through some process. The main part that need to be studied was pick and place part for both of the
machine which is SDKZ and RD708 machine.
In the experiment work, the project was divided into three major phases which is including design 3D CAD,
modification of the design and concept applied to the machine. The experiment started up with designing a 3D CAD
of the machine. Designing of semi auto SDKZ machine was referred exactly similarly to the industry work in the pick
and place process. The component then will be assembled to build an exact machine. The experimental work
continued with modification of the pick and place of cam in the SDKZ machine. The pnp part then will be upgrade so
that it will suitable to the machine and can increase the productivity of the switch. The modification of pnp part then
will be applied to the SDKZ machine. If the design fails to fulfil the project specification, it will redesign back until it
will achieve the target.

4.0. RESULT & DISCUSSION

The purpose of the experiment work is to investigate the cause of reason why semi auto machine does not achieve
their target monthly and produce less product than manual machine. For this project, the analysis of operational time
will be set to be the important parameter. So this process of work can show parameter or calculation that used for
design work. Overall this chapter was discussed about investigation and analysis of automation machine in actual
condition. By record both of the operational time for manual and semi auto machine, the comparison can be made so
the problem can be identified. Then, the expected of time taken and time loss for the operation for semi auto machine
after had been modified also need to be taken and considered. The part of pick and place of cam SDKZ switch is the
main part that will be discussed in this chapter. This part need go through “kaizen” process where some modification
had been constructed. In the other word, this study focused on the modification or change of design for the machine by
constructing and comparing the result on different design.

4.1. Before Modification of Pick and Place Cam Part


4.1.1. Operational Time of SDKZ Switch
From the table above, there were 2 different values was taken which is for manual jig and semi auto machine. From all
value above, the average of time taken for manual jig shown that the values is small than the semi auto machine. It
means the efficiency of manual jig is higher than the semi auto machine. The operational time for manual jig is 6.4s
for one complete cycle to assembly SDKZ switch while the time taken for the semi auto machine to assembly one
SDKZ switch is 13.04s which is longer than the manual line. From the observation, a pick and place of cam part is
major cause due to this time taken problem. Firstly, the cam need to be inserted into the tunnel. After a while the cam
then will finished and cause the machine to be stopped. So the operator are going to fill up the cam into the tunnel
again. By using a stopwatch, a time taken need by the operator to fill the cam into tunnel is about 4 minutes. In that
time, calculation shown that the productivity of switch can be affected.

4.1.2. Usage of Labor


In term of labor usage, ALPS ELECTRIC industrial use many operators to assembly a SDKZ switch. In manual line,
the number of operators is 7 persons including the operator that do the quality check of the switch. The manual line
then change to the semi auto machine so the usage of labour can reduce. The comparison between manual and semi
auto line, the usage of labour is totally different. In semi auto line, the operators is 4 persons only including quality
check of the switch. When production loss is higher, the productivity of the switch can lifted up.

4.1.3. Productivity
Based on the calculation of the cycle time, no of workstation and efficiency of the machine, there are different
between both of manual and semi auto SDKZ machine. Cycle time of the semi auto is bigger than the manual
machine. It cause by the desired output rate by semi auto is lower than the output rate come out from the manual
machine. From the calculation of task time, the task time of manual machine is lower than the semi auto. This is
because the process of assembly in the semi auto machine consists of 22 process. While for the efficiency of the
machine, it seems that the manual machine is more efficient than the semi auto machine. It is because there are less
occur happen in the manual machine.

Cycle Time =

Task Time = Time taken for one process

= Sum of the Task Time

Minimum No

Of Workstation =

Efficiency =

4.2. After Modification of Pick and Place Cam Part

Figure 4.1: Complete After Modification


4.2.1. Operational Time
After the modification has been done, the machine was tested to run. Time taken for SDKZ switch to
assembly was recorded to obtain a result. Some calculation had been done to get the time loss. By getting the time
loss, the total of product loss also can be known. By using stopwatch, the time loss that has been obtained is 4 minutes.

4.2.2. Usage of Labour


From the expected result, it shows that the part of the pick and place machine now is fully operate by a motor. There is
no more operators need in this operation. By doing this kind of modification, it seems can reduce the usage of labour.
Semi auto SDKZ line machine now need only 3 operators to operate in this line now.

4.2.3. Productivity
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From the calculated operation time loss, it shows that the total loss is 18 units per hour. This problem is caused by the
time loss of the machine that affect the productivity of the machine. Below shows the example of calculation:

Time Loss = 4 minutes


= 4 x 60s
= 240s

Product loss = =

=
= 18 units

4.3. Discussion Comparison Between Before & After the Modification

From what has been discussed in result process, the modification design process give out the different result. The
amount of the productivity now for the semi auto SDKZ machine is increasing more than before. The calculation of
the productivity shows the efficiency of the machine is increasing from 34% to 56%. This is because of the reducing
of the time loss in the assembling process. Thus, there is less error occurred on the machine anymore.

5.0. CONCLUSION

As a conclusion, the objective of this project was successfully achieved. This project has managed to come out
expected result of the modification of pick and place process part for the cam in the SDKZ machine. This kind of
project also has developed a new design that can reduce the production time of SDKZ switch for semi auto SDKZ
machine. The simulation and drawing using SOLIDWORK help any people in making drawing, analysis and many
more. This project also has taught many kind of thing especially in industrial manufacturing simulation.
RD708 machine was used as a benchmark and the concept of that machine was applied to the SDKZ
machine. RD708 was choose as the benchmark machine because there have part that similarly as the SDKZ machine.
From this project, both SDKZ and RD708 machine has been studied first. This is because both of the machine have
different flow process. The pick and place part from the RD708 was applied and modified at SDKZ machine. From the
project, creativity is an essential factor to modified machine. It is because to modify a machine is the hardest part in
industrial.
On top of that, the productivity of the switch seems to be increasing from before. Hopefully, by doing a
modification to a pick and place part in SDKZ machine, the total time loss can be reduced. This project also had bring
some calculations and comparison between manual and semi auto machine. Thus, from semi auto machine, it then
compared with the latest upgrade SDKZ machine. The time taken, process of the machine and productivity has been
recorded so comparison can be made. By doing some calculations, we know that the efficiency of manual and semi
auto SDKZ machine is totally different.
In term of manpower, both manual and semi auto machine are different. In manual line, the operator that was
used is 8 persons while in semi auto machine, there are 4 operators only. The advantage of using the semi auto
machine is manpower can be reduce thus the productivity can be rise. We know that when the operation is loss or
reduce, the productivity is going up. Through all this matter, all objectives were achieved and this project was succeed
followed all scope works

6.0 RECOMMENDATION

For the recommendation, this project should be developed because it can help in reducing time loss of the machine in
manufacturing process. Other engineer or researcher should develop other part in SDKZ semi auto machine for better
result in increasing the productivity of the switch. This project can give many benefits to many manufacturing factory
or industrial. Developing the style of design process will need more attention of research. If this project can be
continued further, it will give many benefits of developing the manufacturing process.
To improve the effectiveness of the output result for further research, the machine need more kaizen or
improvement. Some of the part of the machine may cause to this problem and failure. On top of that, some manual
part need to be changed also. It is because than manual part is slow than the auto part. For this cases, robotic arm also
can be used at the future to replace the semi auto SDKZ machine.

7.0 REFERENCES
1. PengjiaWang, et al., Modular Design of Machine Tools to Facilitate Design for Disassembly and
Remanufacturing. Procedia CIRP, 2014. 15: p. 443-448.

2. Yin, Y.H., et al., Automating design with intelligent human–machine integration. CIRP Annals -
Manufacturing Technology, 2015. 64(2): p. 655-677.

3. Haik, Y., ENGINEERING DESIGN PROCESS. 1st Edition ed. 2003: Bill Stenquist. 269.

4. Marulcu, I. and M. Barnett, Fifth Graders’ Learning About Simple Machines Through Engineering Design-
Based Instruction Using LEGO™ Materials. Research in Science Education, 2012. 43(5): p. 1825-1850.

5. Cai, L., et al., An approach to optimize the machining accuracy retainability of multi-axis NC machine tool
based on robust design. Precision Engineering, 2016. 43: p. 370-386.

6. Koo, K., et al., Architectural design of an RISC processor for programmable logic controllers. Journal of
Systems Architecture, 1998. 44(5): p. 311-325.

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