AUTO CUTTING DT TRACKING

30TH APRIL 2013

Manufacturing Excellence Team

 1. Machine Description

2. Project Activities
CONTENTS
3. Trouble Shooting & Improvements

4. Summary DT
 Auto Cutting Flash Machine ATOM (FC 1660 2H) D M A I C
1. MACHINE
DESCRIPTION

Double cutting heads for Interlock displayed

high productivity. by projector.
There are 4 tools in every Informing size and side
head, cutting –
position area of shoe (L/R).
punching(2) – marking.

Technical Data
Working Area : 1600 mm x Infinite
Max. Cutting Speed : 60 m/min Multilayer racks, up to Auto nesting
10 rolls material can be program.
Cutting Heads :2 set on the racks. Saving material up to
Proposed to high 5%.File extension *.shc
Num. of Tools (1 head) : 5 productivity. Continuous “ from crispin.
conveyor
Projectors :1 Double automatic Job Order Manager
system.
pincher and roll Program.
Power Usage (avg.) : 4.5 kW Divided 3 area,
material. To set order, qty – size
Unloading –
1st pincher to clamp the – materials used – auto
Dimensions (L x W x H) : 4193x2806x2449mm Cutting –
materials nesting.
Loading area.
2nd pincher to load the Exclude machine
Working area :
Weight : 1700 kg materials program.
1540 x 600 mm
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2. PROJECT ACTIVITIES
Machine Exhibition
Oct. 18th 2011
List of Activity :
1. Introduction ATOM company
profile
2. Introduction Flashcut 1660 2H
ATOM autocutting machine
features
Machine installation
Apr. 23th 2012
List of Activity :
1. Machine and software
installation in Factory #5
2. Network cable installation
Trial , Analysis & Training
Apr. 24th 2012
List of Activity :
1. Trial to cut all kind of textile,
synthetic, foam & texon
material.
2. Analysis & decided number
of layering for each material
3. Training program
a) Mechanical :
Maintenance, Change
Over parts, Problem
Solving
b) Process : Nesting,
Editing, Interlocking,
operational process.
D M A I C
Evaluation trial results
with PWI & Atom Team
May 2nd 2012
List of Activity :
1. Review trial result
2. Plan to move machine to aPIC
3. Communicated to all relevant
department to support this
project.
4. The task of each relevant
department
Relevant Department:
1. ME, PPIC, Material,
Lamination, Engineering,
Dev-Crispin, Production.
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 D M A I C
2. PROJECT ACTIVITIES
Preparation to Implement 1st Review the machine 1st improvement from
Mass Production
the Project performance with supplier mechanical side

May 4th 2012 May 8th 2012 Jul. 02nd 2012 Sep. 03th 2012

List of Activity : List of Activity : List of Activity : List of Activity :

1. Decide kinds of material to cut
considering trial results.
2. Decide the place where the
machine will be install for long
time.
3. Communicated the project to
all relevant department
1. Start run with production
order (Derby II K & LK
Trainer)
2. Evaluation period
a) Output daily monitoring
b) Quality daily monitoring
c) Downtime daily
monitoring
3. Trouble shooting with Atom
1. Evaluation the Machine
performance
2. Decided 7 points to improve
by Atom Team
a) Reduce noise
b) Changeover time
c) Material Handling
d) Ergonomic design for
roller material.
e) Increase Lifetime of knife
f) Nesting program
g) Yield
1. Review & analysis customer
demands for material loader
2. Submit problem issues to
supplier
Point to improve :
1. Improve design current
material loader to ergonomic
loader.

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 D M A I C
2. PROJECT ACTIVITIES
2nd improvement from 3rd improvement by Ongoing Activity Repairing Cutting Belt
software side Atom Technician

Sep. 11th 2012 Oct. 02nd & Oct 30th 2012 Dec. 20-27 2012 Dec. 26-27 2012

List of Activity : List of Activity : List of Activity : List of Activity :

1. Review efficiency for nesting 1. Looking for the root cause of 1. Looking for the root cause of 1. Gluing belt to re connecting
system with supplier problem (vacuum suddenly projector lamp stopped. 2. Sanding surface of belt after
2. Submit problem issues to stopped working) 2. Check lamp condition glued.
supplier 2. Check inverter 3. Check mouse optic condition
3. Find out the root cause of
machine Point to Improve
Point to Improve Point to Improve
Point to improve : 1. Patching the torn part of the
1. Inverter & power supply 1. Replace projector lamp with belt.
1. Upgrade software layout auto system new one. 2. Gluing area of ​the connection
nesting from echonet to 2. Install pipe to throw hot air to reconnect
flashnest. from the pump outside.
3. Replace mouse with new one
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 D M A I C
3. Trouble Shooting & Improvements
BEFORE DESCRIPTION AFTER DESCRIPTION
Punching was broken Punching was broken
Impact: Impact:
1. Punch can’t 1. Due to limited part
working from Atom, we
replace with
Requirements: bicycle whole
1. Change punch with spokes
new one 2. Cutting result
meets standard
08.01.2012 08.01.2012
Status : DONE

Cutting Belt Broken Change with new belt

Impact: Impact:
1. The machine can’t 1. Keep machine
working performance
2. Reduce Downtime
Requirements:
1. Change belt with Status : DONE
new one

08.11.2012 08.12.2012

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 D M A I C
3. Trouble Shooting & Improvements
BEFORE DESCRIPTION AFTER DESCRIPTION
Vacuum Suddenly Off Vacuum suddenly off
Impact: Impact:
1. Cutting result 1. Cutting result well
disorganized organized
2. Reduce down time
Requirements:
1. Crosscheck the Status : DONE
root cause of
problem by
Technician
10.02.2012 10.03.2012

Un-optimize auto Upgrade software

nesting optimize auto nesting
Impact: Impact:
1. Lot of mat’l waste. 1. Saving material
2. Big gap (distance) use
between shapes 2. Minimize waste
especially between 3. Small gap
different size (distance)
Requirements:
1. Priority big size in Status : DONE
07.02.2012 07.09.2012
first nesting.

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 D M A I C
3. Trouble Shooting & Improvements
BEFORE DESCRIPTION AFTER DESCRIPTION
Knife Holder Broken Knife holder broken
Impact: Impact:
1. 1 head can’t 1. 2 head can
working working
2. Reduce Replace with 2. Increase
productivity
new one by productivity

Requirements: ATOM Status : DONE

1. Replace with new
one
10.09.2012

Knife house (cups Knife house (cups

holder) tear holder) replace with
Impact: new one.
1. Disturbing cutting Replace with Impact:
result. 1. Sustain cutting
2. When the cutting
new one by result organized
holder opened
Requirements:
ATOM 2. Minimize waste
3. Optimize machine
1. Replace with new performance
one
06.21.2012 06.12.2012
Status : DONE

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 D M A I C
3. Trouble Shooting & Improvements
BEFORE DESCRIPTION AFTER DESCRIPTION
AT1D012B adjustable Replaced with new one
pneumatic chuck 0.64 Impact:
mm broken 1. 2 head can
Impact: working together
1. 1 head of the Knife 2. Keep stable
can’t working productivity

Requirements: Status : DONE

1. Replace with new
one
10.09.2012 12.15.2012

Projector suddenly Replaced with new one

stop projector .
Impact: Impact:
1. All process cutting 1. Sustain cutting
stopped. process
Requirements: 2. Optimize machine
1. Replace projector performance
lamp with new one especially
2. Install hot air from projector lifetime
the pump outside.
12.17.2012 12.20.2012
Status : DONE

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 D M A I C
3. Trouble Shooting & Improvements
BEFORE DESCRIPTION AFTER DESCRIPTION
Optical Mouse not Replaced with new one
working Impact:
Impact: 1. Can do all
1. Can’t operating
Replaced commands in the
some commands
in the computer.
with new one machine

2. Can’t calibration Status : DONE

the machine
Requirements:
1. Replace with new
12.20.2012 one

Cutting Belt Broken Glued the belt

Impact: Impact:
1. The machine can’t 1. Keep machine
working performance
2. Down Time 23
days (33 hours) Status : DONE
Requirements:
1. Need original glue
from atom.
2. Change belt with
12.22.2012 12.27.2012
new one

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 D M A I C
3. Trouble Shooting & Improvements
BEFORE DESCRIPTION AFTER DESCRIPTION
Machine not working Machine Running with
due to projector off. projector.
Impact: Impact:
1. Can’t see the 1. Machine can
components working with
position. normal condition.

Requirements: Status :DONE

1. Replace with new
one 01.07.2013
12.20.2012

Right side of chuck not Replaced adjustable

working due to broken chuck with new one &
on O-Ring the machine Running
Impact: with 2 cutting head.
1. Chuck can’t Impact:
working 1. Machine can
working with
Requirements: normal condition.
1. Replace with new
one as soon Status :DONE
03.22.2013 03.25.2013

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 D M A I C
3. Trouble Shooting & Improvements
BEFORE DESCRIPTION AFTER DESCRIPTION
Material stuck in the
Puncher hole

Impact:
1. Machine ERROR
Need to Order original
Part (Punch) diameter Status :ONGOING
Requirements:
1. Need to cleaning 1 & 1.5 mm
and puncher need
using original part.
28.04.2012

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 D M A I C
4. Summary Machine Down Time
233
240
No Event Freq. (times)
220
200
1 Computer 233 180
160 Down Time Punch
2 Vacuum 101 140
average = 5 times/day
120 101
3 Drill/Punch 28 100 @+- 8 minutes/DT
80
4 Projector 16 60
40 28
16 16 14
20 8 6
5 Belt Torn 16
0
Computer Vacoom Drill / Belt Projector Knife Mouse Knife Cover
6 Knife Broken 14 Punch

7 Mouse 8
Computer Vacoom Drill / Punch Belt Projector Knife Mouse Knife Cover

8 Knife Cover 6
Data collected start from May ‘12 ~ April 2013
Action Plan:
Change Punch by Original Puncher (need to order)

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THANK YOU!
Manufacturing Excellence Footwear