Maintenance & Automation

Improvement Activities

April 2022

Sensitivity: Public
 Maintenance improvement activities
Zero Breakdown activities DONE
Improvement Plan Photo

1. Foaming platform BI line – rotational table

modification – adding safety switches,
replace the cables with one single cable

Benefits – In case of the inductive sensor is

not detecting the metal shaft during the table
rotation the mechanical switches are doing this
job.

2. Final platform – rotational table modification

– adding safety switches, replace the cables
with only a single cable

Sensitivity: Public
 Maintenance improvement activities
Preventive maintenance activities
Improvement Plan Photo

3. Automatic lubrication system for U-

Shell machine DONE

Benefits:
Increase the lifetime of the metal parts.
Offers the necessary grease protection
for the forming metal rollers.

Sensitivity: Public
 Maintenance improvement activities

Improvement Plan Photo

4. Adjusting the electrical configuration of the DONE

injection molds according to machine electrical
configuration.

Benefits: Maintenance cost reduction

Reduce the costs for creating special cables for
each mold. We have standardized the rule of
the electrical connection between the mold and
the injection machine.
This improvement was applied to 50 molds.

Sensitivity: Public
 Maintenance improvement activities
Improvement Plan Photo
Before After
5. The plastic cable protection arrived with the ss
U-shell robot was unproper.

Benefits: The robot have to place the u-shells

in two manners / directions in order to go up the
u-shells on the platform and in the rotation
mode.
By replacing the cable protection, the no
breakdown was eliminated.

Zero Breakdown activities

Sensitivity: Public
 Automation improvement activities
Cycle time improvement for Foaming Cabinet Line FS/BI : DONE

Problems addressed Actions

 Improve cycle time  Anticipation of upward diverter position, Software modification

4 SEC

Transfer time
24 sec 20 sec
BEFORE AFTER

4 SEC

Transfer time
24 sec 20 sec
Sensitivity: Public
 Automation improvement activities
Cycle time improvement for Foaming Cabinet Line FS/BI : DONE
Problems addressed Actions

 Improve cycle time

 Increase inverter frequency/motor speed;
 Decrease transfer time from out of foaming to first work station from 40 sec to 36 sec

4 SEC
REDUCTION
40 sec 36 sec

Sensitivity: Public
 Automation improvement activities
Improve cycle time – Preassembly DONE
Problems addressed
 Improve cycle time  Improve cycle time

Actions

 Decrease transfer time from 15 sec to 10 sec  Decrease transfer time from 18 sec to 15 sec
 PLC Software modification!  ABB Robot software modification!

Sensitivity: Public
 Automation improvement activities
Decrease stoppages_Zero Chokotei – Assembly line
 When line number 6 was full, the product that
was loaded from Assy line are still blocked at
the last conveyor because it has no direction
Problems addressed
 When line 11(BI) unload the products, FS out
conveyor to assy was blocked until line 11
finished complete unloading
DONE
 No synchronization between conveyor that
load the cabinet to vacuum line and carousel.
Was lost one cabinet at 2 boxes.

Actions

 PLC software modification,improve cycle time
with 3 sec.
 When line 11 was unloading, FS product  PLC software modification, synchronize the
needed to wait until the line was finish speed of the motor
unloading, now has been synchronized to
transfer 1 product from line 11 and pass 1 FS
product , software modification!

Sensitivity: Public
 Automation improvement activities
Decrease stoppages – Preassembly/Assembly
 Bad quality of the sticking evaporator on the
inner liner
 PLC software modification for keep the inner
in position in order to stick all the surface of
the evaporator!
Sensitivity: Public
Problems addressed
 When the local emergency stop is pressed
from the packaging line, the last station(rotary
table) lost the information about the action and
kept blocked after depress the emergency
Actions
 PLC software modification for continue the
actions automatic after depress the
emergency button!
DONE
 In mix production BI and FS the equipment
had a lot of stoppages according with wrong
data sent to the PLC
 PLC software modification to send correct
data and eliminate the stoppages!
 Automation improvement activities
Cycle time Improvement – Packing line DONE

Problems addressed
 One cabinet spend ~ 15 min for load/unload at the transfer to warehouse  Desynchronization between load and unload of
product that create empty space between them(Final
quality check)

Actions

 Adjust conveyors speed  Adjust conveyor speed

 PLC software modification  PLC software modification for tandem load/unload!
 Reduce with ~2 minute the transfer time

Sensitivity: Public
 Automation improvement activities
Decrease stoppages – Packing line DONE

Problems addressed
 Missing timeout warning signal final quality check  Stoppages on the elevator movement

Actions
 Installation of the warning light after 17 seconds, PLC hard/software  PLC software modification, adjust software parameter of the servo drive
modification!

Sensitivity: Public
 Automation improvement activities
Cycle time Improvement – Performance Test line In/Out DONE

Problems addressed
 Improve cycle time  Improve cycle time

Actions

 Adjust and synchronize the conveyor speed , reduce cycle time from 18 min to 15 min  Adjust conveyor speed
 PLC software modification for in/out!  PLC software modification!
 Decrease transfer time from 70 sec to 59 sec ,
software modification!

Sensitivity: Public
 Automation improvement activities
Decrease % of rejected product - Sorting Area DONE

Problems addressed Actions

 From 100 products aprox 40 cabinet was directed to reject  Decrease percent of rejected product from ~40 % to ~2 %
conveyor according with lost information about the diverting  Modify the PLC software program
to sorting lines  Modify the position of the sensors

38 %
~40 % ~2 %

Sensitivity: Public
 Automation improvement activities
Traceability for process parameters - Foaming cabinet Side B (FS) –SCADA system: DONE
Plan Actions/Benefits
DONE
 Automation of Quality and Production Controls for PU foaming parameters FS cabinets,  Integration of PLC on the OPC server data collection
 Generate the PLC tags on Scada System
Side B.  Develop the interface
 Test the interface
 Put in function on the equipment area

Traceability of each foamed cabinet with its foaming

parameters
Supervise complete production, in real time and on
historical and statistical bases

Monitor process parameters:

 Poured weight;
 Iso and Pol temperatures (set and actual);
 Iso and Pol pressures (set and actual);
 Oven temperature
 Fixture walls temperature
 Vaccum pressure
 Weight empty cabinet
 Weight foamed cabinet
 Avalalility of equipment
 Wait infeed
 Wait outfeed
 Product rate
 Piece rate

Sensitivity: Public
 Preventive and corrective maintenance activities
DONE

Weekly meeting together with HQD team and maintenance team, in order to
establish the necessary maintenance works for the weekend period.
Sensitivity: Public
 Automation Project

Sensitivity: Public