Robot #2 - 2019

Colpitt #1 Colpitt #2
Month Downtime Quantity of shift Month Downtime
April 262 31 April 313
May 157 54 May 351
June 226 63 June 338
July 300 69 July 278
August 163 66 August 227
September 139 48 September 95
October 444 75 October 399
November 184 46 November 173
December 1532 27 December 70
January 4357 34 January 292
February 148 54 February 45
March 187 39 March 277
Total of hour/shift
Shift (minute)
 Robot#2 - 2020
Colpitt #2 Colpitt #1 Colpitt #2
Quantity of shift Month Downtime Quantity of shift Month
66 April 60 54 April
63 May 187 44 May
69 June 147 47 June
70 July 111 53 July
70 August 121 37 August
45 September 133 18 September
75 October 153 57 October
29 November November
11 December December
34 January January
41 February February
55 March March
Total of hour/shift
Shilf( minute)
2020
Colpitt #2
Downtime Quantity of shift
327 61
285 51
281 62
210 55
155 39
115 18
420 61
 Robot #2 - 2019
Colpitt #1 Colpitt #2
Month Downtime Quantity of shift Month Downtime
April 262 31 April 313
40 30
May 54 May
117 321
June 226 63 June 338
95 19
July 69 July
205 259
20
August 163 66 August
207
10
September 139 48 September
85

88
399
October 75 October
311
45
93 10
November 46 November
91 163

1435
December 27 December 70
97
4140 17
January 34 January
217 275
37
February 54 February 45
111
47
March 39 March 277
140
Total of hour/shift
Shift (minute)

Robot#2 - 2020
Colpitt #1 Colpitt #2
Month Downtime Quantity of shift Month Downtime
20
April 60 54 April
307
110 45
May 44 May
77 240
20 30
June 47 June
127 251
31
July 53 July 210
80
August 121 37 August 155
 60
September 133 18 September
55
October 153 57 October 420
November November
December December
January January
February February
March March
Total of hour/shift
Shilf( minute)
Colpitt #2 Colpitt #1 - Robot #2 - 201
Quantity of shift Dowtime
66 Month Tube stuck Not home
April 262
63
May 117 40
69 June 226
July 205 95
70
August 163
September 139
70
October 45 399
November 91 93
45
December 97 1435
January 217 4140
February 111 37
75
March 140 47
Total of hour 134.98
Minute/shift 13
29

11

34

41

55

Colpitt #2 Colpitt #1 - Robot #2 - 202

Quantity of shift Dowtime
Month Tube stuck Not home
61
April 60
May 77 110
51
June 127 20
July 80 31
62
August 121
September 133
55
October 153
39 November 75
 December
18
January
61 February
March
Total of hour 16.45
Minute/shift 46

Month downtime Not home

January 4357
Feb 148
March 187
April 60
May 187
June 147
July 111
August 121
September 133
October 153
November 147
December 75
January 80

Robot #2 (Hour)
8073
70
60
50
40
30
20
10 2 3 3 2 2 2 2 3
1
0

Robot #2 (minute/shift)
140128

120

100
 Robot #2 (minute/shift)
140128

120

100

80

60

40

20 7
3 5 1 4 3 2 3 3
0
Colpitt #1 - Robot #2 - 2019 Colpitt #2 - Robot #2 - 2019
Dowtime
Quantity of shift Month Tube stuck Not home
31 April 313
54 May 321 30
63 June 338
69 July 259 19
66 August 207 20
48 September 85 10
75 October 311 88
46 November 163 10
27 December 70
34 January 275 17
54 February 45
39 March 277
134.98 47.63
13 5

Colpitt #1 - Robot #2 - 2020 Colpitt #2 - Robot #2 - 2020

Dowtime
Quantity of shift Hour Minute/shift Month Tube stuck Not home
54 1 1 April 307 20
44 1 2 May 240 45
47 2 3 June 251 30
53 1 2 July 210
37 2 3 August 155
18 2 7 September 55 60
57 3 3 October 420
75 1 1 November 513
 December
January
February
March
16.45 38.43
46 6

Quantity of shift Hour Minute/shift Month downtime Not home

34 73 128 January 292
54 2 3 Feb 45
39 3 5 March 277
54 1 1 April 327
44 3 4 May 285
47 2 3 June 281
53 2 2 July 210
37 2 3 August 155
18 2 7 September 115
57 3 3 October 420
43 2 3 November 306
75 1 1 December 513
65 1 1 January 158

#2 (Hour) Robot #2 (Hour)

9
8
7
7
6 5
5 5
5 5 5
5
4 4
3 3
2
2
1
2 2 2 3 2 1 1 1
0

(minute/shift) Robot #2 (minute/shift)

12

10
9
8 7
(minute/shift) Robot #2 (minute/shift)
12

10
9
8 7
6
5 6
6 5 5
5
4 4
4

7 2 1
2 3 3 3 1 1
0
Robot #2 - 2019

Quantity of shift
66
63
69
70
70
45
75
29
11
34
41
55
7.63
5

Robot #2 - 2020

Quantity of shift Hour Minute/shift

61
51
62
55
39
18
61
50
8.43
6

Quantity of shift Hour Minute/shift

34 5 9
41 1 1
55 5 5
61 5 5
51 5 6
62 5 5
55 4 4
39 3 4
18 2 6
61 7 7
65 5 5
50 9 10
37 3 4

Robot #2 (Hour)
9

5
5 5
4
3 3
2

Robot #2 (minute/shift)
10

7
Robot #2 (minute/shift)
10

7
6
6
5 5
4 4
4
 5000

4500

4000

3500

3000

Minute
2500

2000

1500

1000

500
95
262 40
117 226 205
0
April May June July

200

180

160

140
110

120
Minute

100

80

60

40 77
 Minut
100

80

60

40 77
60
20

0
April May

Main issue/
Repeating issue Whe
Transfer Unit
Colpitt #1:
1) FY2019: 134.98 Hrs
Rail
Stop (13 minutes/shift)
2) FY2020: 15.20 Hrs stop
(3 minutes/shift) until
Sep.
Colpitt #2:
1) FY2019: 47.63 Hrs Stop
(5 minutes/shift)
2) FY2020: 29.88 Hrs stop
(5 minutes/shift) until
Gap between rail an
Sep.

Transportation
Mandrel

Optical sensor

Servo
 Colpitt #1 - Robot #2 - 2019

Not home
4140 Tube stuck

1435

95 399
226 205 93 217 37 47
7 163 139 45 91 97 111 140
y June July August September October November December January February March

Month

Colpitt #1 - Robot #2 - 2020

20
110

Not home
31
Tube stuck
153
133
127
121

77 80
 Not home
31
Tube stuck
153
133
127
121

77 80

May June July August September October

Month

Where Description Roo

Rail Material stuck on Rail Not good material and rail's g

Parameters of frequency cont

rail and bowl

Gap between rail and bowl Rail and bowl are misaligned No POKA-YOKE Mechanical

Transportation servo cannot move

Transportation mandrel Servo error
 Lower latch pin broken; canno
Mandrel Lower gripper movement timed out cannot grip to pull down the l

Limit sensors of lower gripper

Mandrel carrier not in position Outer stopper slipped and ma

be returned, so lower gripper

Dust covers the sensor's vision and

Optical sensor make its signal is always ON, so robot Not mentioned in PM procedu
still picks up tube when there is no clean the sensor head.
tube

Use control panel to remote,

Servo Robot looses home positions positions! (2 December, 2019

Battery is disconnected, so los

January, 2020)
 Colpitt #2 - Robot #2 - 2019
450

400

350 88
30

300
17
19
250
Minute

Not home
20
Tube stuck 200

338 10
313 321 311
150
275
259

100 207
10
163

50
85
70
45
0
April May June July August September October November December January Febru

Month

Colpitt #2 - Robot #2 - 2020

450

400

350

20
300

45 30
250
Minute

Not home
Tube stuck 200

150 307

240 251
100 210
60
155
 250

Minut
Not home
Tube stuck 200

150 307

240 251
100 210
60
155

50
55

0
April May June July August September

Month

Rootcause Action plan

material and rail's groove is very fit with tube Increase dimension of linear's groove

ers of frequency controller are not suitable for after realigned linear and bowl, inspect the
owl vibration to find out suitable parameters

-YOKE Mechanical Realign rail and bowl

or
 Had PM item check (VEM02008 - 6.2.2.14), so
ch pin broken; cannot return, so lower gripper just replace when broken
ip to pull down the latch pin

Check and fix the limit sensors

sors of lower gripper is loosened and broken

Get new dimension for outer stopper; just one

pper slipped and make lower latch pin cannot position and cannot slip
ed, so lower gripper cannot grip

tioned in PM procedure and production cannot

sensor head. PM item check

rol panel to remote, after that robot lost home

! (2 December, 2019)

Automation team support to write CM

procedure
disconnected, so losing home position (2
2020)
9

17

Not home
Tube stuck

275 277

70
45

December January February March

Not home
420 Tube stuck

60
 Not home
420 Tube stuck

60

55

September October

PIC Impletement
date

Thang Luong team 01 Dec 2020 (Colpitt #1)

02 Dec 2020 (Colpitt #2)

Thang Luong team 01 Dec 2020 (Colpitt #1)

02 Dec 2020 (Colpitt #2)
Thang Luong team Done on 30 March, 2020

Vang (VEM02008)

Tran Dai 20 December, 2020

Effectiveness

Stuck on rail

Stuck at gap
 Transportation

"Mandrel not in position" error doesn’t happen again

(outer stopper improvement), Limit sensor was fixed,
the error just happens when lower latch pin broken

Lower latch pin broken

Dust covers sensor h

Robot 2: losing home

 FIT

Frequency controller Groove

 Limit sensor

Dust covers sensor head always ON

video

sing home
FIT

Tube
Old stopper stopper slipped

Video

the Hole fit with bolt

New stopper No gap

 Transfer Unit ( 15/10/2019)
Colpitt #1
Month No information Sheet is not cut Sheet fall impacted needle
October 20 54 24 15
November
December
January
February
March
April
May
June
July
August
September
Total of hour/shift
Shift (minute)

Downtime_Colpitt #1
60
54

50

40
Minute

30
24
20
20
15

10

0
October November December

Month
2019) Transfer Unit (
Colpi
total of Downtime Quantity of shift Month No information
113 30 October 17
November
December
January
February
March
April
May
June
July
August
September
1.88 Total of hour/shift
4 Shift (minute)

tt #1 Dow
18
17
16
16

14

12
11
No information 10
Minute

Sheet is not cut

Sheet fall 8
impacted needle
6

0
December October
 Transfer Unit ( 15/10/2019)
Colpitt #1
Sheet is not cut Sheet fall Total of downtime Quantity of shift
11 16 44 38

0.73
1

Downtime_Colpitt #2
7
16

11

No information
Sheet is not cut
Sheet fall

October November December

Month