The
Automation System
(May 2022 - Sep 2022)
This is my first engineering internship and I was responsible for brainstorming a solution to improve the changeover of the production process by using an automation system known as Karakuri in Japanese. I used my engineering knowledge in this project to conceptualize 3D design, material selection, installation, and system test runs.
ExplorePROBLEM STATEMENT
The Company wants to create an automation system that can support operators in the packing station of the assembly line. A few problems need to be solved using the system: improving the operator's working ergonomics, convenience, and comfort. Also, the system should help save downtime by swapping container during the packaging process and using spare time to produce more products.
Project Target
Research and Analysis
To design a system that fits a variety of products, I must have a good understanding of the product's type, size, and material. I collected all critical information about each product and its variation and analyzed it to find the design's common trait.
3D design
To get the best visualization of the system, they need to be simulated through 3D software like Creo and SolidWorks. I used the 3D design to explain my idea to colleagues and managers to get their feedback.
Test Run and Installation
All new improvements need to be tested to evaluate effectiveness, and my design has also gone through many reviews. In the end, being installed and put into mass use is the project's success.
Steps
1. Collect and Analyze data
Each function in the company will
keep different information about the product
Collecting such a data to analyze and
generate the design for the system is priority.
2. 3D design of the system
With all the reference data of the product,
I have to propose a 3D design of the
system that fits most of the
production good in the plant.
3. Assembly and Installation
Based on the 3D drawing of the system,
the system will be built and do a test
run for the pilot line. The success
of that production line will be replicated
to the entire factory.
4. Evaluate the effectiveness
Evaluate the quality and effectiveness
of the automation system design for the
pilot line. The success of that pilot
line will be replicated to the entire factory.
My Approach
June 2022
The two design and 3D printed of them
The Beginning
I started by collecting information about the products produced in that line. There are over 16 lines in the plant and over 2000 variations of the products. One of the project's challenges is gathering all that information and filtering out the most important one for the system design. I soon picked up some critical information I needed, such as the product's size, family, and packages.
The Process
The system's design must be based on that data so no one will be able to challenge that design. I sketched out my desired shape and made a 3D drawing of the system. I had to present and communicate the design with the review team many times, and the final one took almost 2 months to complete.
The Result
After the final design is approved, the installation and performance are quickly completed within the next month. Finally, the evaluation is complete, and the company invests in my project because the system has reduced 30 minutes of downtime per day and $400.000 a year in revenue savings.
