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waste elimination
ASSY. PRODUCTION ENGINEERING
AMIR ASYRAF BIN MOHAMMAD REDZUAN
13838
Kaizen Presentation - Bonding Detector
? UV Bonding Machine
C Mushashi Shotmini 100s C table
top robot
C Syringe tube
? 100cm3 capacity
? High opacity C prevent bond
? Bonding process
C Assemble L254
Focus Motor &
Holder Sensor
C UV Bond qty
per/pcs :
BONDING
AREA
Start
Dispense
CuringInspection
End
Unnecessary frequent refilling
needed
PROBLEM
? Operator has difficulties to
determine content level ?
reach minimum level
Frequent refilling
(40times/month)
? Quality Problem C Part not
properly bonded
Too dependent on
human judgment due
to syringe opacity
恬I宀にたよる朕登
協ojな咾/rg
Kaizen Presentation - Bonding Detector
Unnecessary frequent refilling
needed
after UV bond reach below
minimum level, dispensing
pressure inconsistent
(2) Concept of minimum level
after UV bond reach below
minimum level, dispensing pressure
inconsistent
History-EC335 CCD UV bonding
(Average 2times/mth)
(gmbr)
(countermeasure-frequent refilling)
Visual
Inspection
Curing
PLUNGE
R
MAGNET
UV
Bonding
Sensor
triggered?
END
Refill
START
SENSOR
When leveled with
magnet - sensor triggered
and relay will contact and
send signal to emergency
switch C operation stops
If magnet inside
plunger not level with
sensor C
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
Before After
Frequency 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 2112
? Expansion to all EF lenses
models
Model
L254
L35
L240
L114/
L116
L248
MC1
COMPLETE
D
MC
2
MC
2
MC
2
MC
2
MC
2
Kaizen Presentation - Bonding Detector
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Kaizen Presentation - Bonding Detector

  • 1. waste elimination ASSY. PRODUCTION ENGINEERING AMIR ASYRAF BIN MOHAMMAD REDZUAN 13838
  • 3. ? UV Bonding Machine C Mushashi Shotmini 100s C table top robot C Syringe tube ? 100cm3 capacity ? High opacity C prevent bond ? Bonding process C Assemble L254 Focus Motor & Holder Sensor C UV Bond qty per/pcs : BONDING AREA Start Dispense CuringInspection End
  • 4. Unnecessary frequent refilling needed PROBLEM ? Operator has difficulties to determine content level ? reach minimum level Frequent refilling (40times/month) ? Quality Problem C Part not properly bonded Too dependent on human judgment due to syringe opacity 恬I宀にたよる朕登 協ojな咾/rg
  • 6. Unnecessary frequent refilling needed after UV bond reach below minimum level, dispensing pressure inconsistent
  • 7. (2) Concept of minimum level after UV bond reach below minimum level, dispensing pressure inconsistent History-EC335 CCD UV bonding (Average 2times/mth) (gmbr) (countermeasure-frequent refilling)
  • 9. When leveled with magnet - sensor triggered and relay will contact and send signal to emergency switch C operation stops If magnet inside plunger not level with sensor C 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
  • 10. Before After Frequency 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 2112
  • 11. ? Expansion to all EF lenses models Model L254 L35 L240 L114/ L116 L248 MC1 COMPLETE D MC 2 MC 2 MC 2 MC 2 MC 2