OCTOBER 20219MANUFACTURING TECHNOLOGY INSIGHTSbuilding are concept design, design review, manufacturing of parts, assembly of machines, control panel wiring and installation, hydraulic piping and power pack installation, and trial & commissioning. Concept Design: Inputs required for SPM design, such as product volume, product process flow, product drawing, etc. are captured in this stage. The cost centre number is generated for the identification of machines. The plan for the machine completion is of the machine. Depending on the complexity of the machine, the plan is designed. The concept is designed based on inputs given by the customer. In basic, concept design feasibility check is done by a cross-functional team. If a similar type of machine is available in the plant, Things Got Wrong (TGW) & Things Got Right (TGR) are referred to avoid repetition of work. SPM design is done with Solid works 2018 SP0.1 software. In design, standard parts are for the machine completion is the tool room, test equipment, IOT laboratory, and Cobots simulation centre to explore various trials and process design, which helps for speedy machine assembly. In-case there needs any corrections for the parts received, the in-house tool room facility supports the modifications.Control Panel Wiring and Installation:Electrical teams work in parallel, wiring control panel as per electrical drawings provided by the programmer. Identification tags are given to each cable. HMI is used to store the data. The sensor installation, FRL unit, cylinder, light curtain cabling programming is done in this process. As per the sequence of all operations, the program is designed considering a minimum interval of time.Trial and Commissioning:Trials are conducted on the machine to get required part specifications and cycle time. After several trials, parts are inspected by QA. A plant safety officer conducts a safety audit. After the approval from quality and safety, the signoff document for cycle time chart, inspection reports, and safety audit report, the machine is ready for handover to the production team. Training is provided to the operator on machine operation and preventive maintenance practices. Plant members validate the machine, and only then the machine is shifted to a specified plant for production.Salient Features of Special Purpose Machines (SPM's)· High-Speed Spindles (RPM 4500 for reduced cycle times)· SMED concept ­ changeover time between components is less than 5 minutes· Close positional tolerances of + / - 0.05 mm with Ra values 0.8 microns· Hydraulic toggle link mechanism for rigid component clamping· Heavy-duty spindle mechanism· Multi-position milling for enhanced dimensional stability· Lead screw tapping operation for precise pitch and thread dimensions· Hydraulically operated chucks for centralizing· High productivity ­ 17 operations ­ 10 Sec ­ One operator· Multiple spindle operation· Walking beam principle for component indexing· Auto leak and flow checking· Auto Good and Not-Good component sorting· Robotic Pick and PlaceHydraulic Piping and Power Pack installation:Hydraulic cylinders and the hydropower pack are installed at the later stage, complying with all pressure tests.Sigma Technology Centre Performance since Inception:· Special Purpose Machines built and commissioned ­ 1313 Nos (Simple to Complex)· Developed Holding and assembly Fixtures >1000 Nos · Implemented Low-Cost Automation Projects > 350 Nos · Developed Heavy duty Machines > 20 Nos · Installation of Robotics> 15 Nos · Industry 4.0 Projects > 20 Nos · Productivity Enhancement > 25 percent· Operator Fatigue Eliminated by 90 percent· Cost advantage over in-house SPM manufacturing > 40 percent· Safety Enhanced by 100 percent (Zero accidents reported since last 28 months) Highly engineered production equipment with World Class engineering capabilities is manufactured with highly customized machinery and extensive robotics utilization, which boosts overall productivity & quality performance and reduces cost
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