Sampath Kumar (சம்பத் குமார்)

Machining is the most prevalent manufacturing operation in terms of volume and expenditure. Machining operations of complex parts need to be properly thought in order to save time and improve the competitiveness of the parts. Often, jigs and fixtures are overlooked in milling processes, as an auxiliary tool, but these can help in optimizing a machining process as a part of continuous improvement.
The method used for this study was base an increasing demand forecast of a complex part, called… Meer weergeven

Machining is the most prevalent manufacturing operation in terms of volume and expenditure. Machining operations of complex parts need to be properly thought in order to save time and improve the competitiveness of the parts. Often, jigs and fixtures are overlooked in milling processes, as an auxiliary tool, but these can help in optimizing a machining process as a part of continuous improvement.
The method used for this study was base an increasing demand forecast of a complex part, called Winding cone, which implies a reduction in the takt time from 4.6 to 2.6 minutes per part. This research tries to establish the best solution for the project, which was divided into four phases: research, design, machining, and implementation. The design phase was based on the methodology of Design for Six Sigma methodology (DFSS) for the fixture. The project's critical outputs were harvested during the implementation phase. The newly designed and produced modular jig system is able to deal with 12 parts per cycle, proving to be able to increase the number of parts machined per day by 32%, with expected savings of more than 6000 euros per year. This drastically reduces the lead times for new parts, which is crucial for a small-medium enterprise stay competitive. The new jig design and fabrication allowed comfortable loading and unloading of parts. Minder weergeven

This book gives an insight on how an often-overlooked jig and fixture used as a
manufacturing aid to produce a product and essential for delivering products reliably
and repeatedly with high quality. This continuous improvement project of a machining
process was applied to winding cones used in overhead garage doors. The improvement
was a necessity with a forecast for 2019 estimating the need for 43% faster production
cycle (takt time) compared to the previous year. Hence, the… Meer weergeven

This book gives an insight on how an often-overlooked jig and fixture used as a
manufacturing aid to produce a product and essential for delivering products reliably
and repeatedly with high quality. This continuous improvement project of a machining
process was applied to winding cones used in overhead garage doors. The improvement
was a necessity with a forecast for 2019 estimating the need for 43% faster production
cycle (takt time) compared to the previous year. Hence, the main objective was to
reduce the machining time required per part by designing a modular jig system, ideally
with 12 parts per cycle.
To make the work in an organized structure the project was dived into four phases
namely: research, design, machining, and implementation. The research phase included
in the study of the old jig in use, analysing the process and sketching the basic
requirements. The design phase was based on the methodology of Design for Six Sigma
methodology for the fixture. Different kind of jig components was designed and
assembled using SOLIDWORKS CAD model. The critical review of design iteration was
analysed using SWO analysis (short version of the standard SWOT analysis) for design.
The machining of most components of the jig was done in-house with tacit knowledge
of the machinist instead of using CAM software’s making it first of its kind project in
developing knowledge management in the company for future jig requirements.
The critical outcomes of the project were harvested from the implementation phase.
The newly machined modular jig system proved to have increased the number of parts
machined per day by 32% with expected savings of more than €6000 per year. The added
benefit of a modular jig system was that one base (skeleton of the jig) could be used in
machining different products. This drastically reduces the lead
times for new parts, which is crucial for a small-medium enterprise to stay competitive. Minder weergeven

Machining of complex parts needs to be properly thought in order to save time and cost of making those parts. Jigs and fixtures are often overlooked as an auxiliary tool, but they can help in optimizing a machining process as a part of continuous improvement. The approach to this work was based on the increasing demand of the part named Winding cone 1 for 2019. This implies a reduction in the takt time from 4.6 to 2.6 minutes per part. Thus, this paper aims to find an optimal jig solution for… Meer weergeven

Machining of complex parts needs to be properly thought in order to save time and cost of making those parts. Jigs and fixtures are often overlooked as an auxiliary tool, but they can help in optimizing a machining process as a part of continuous improvement. The approach to this work was based on the increasing demand of the part named Winding cone 1 for 2019. This implies a reduction in the takt time from 4.6 to 2.6 minutes per part. Thus, this paper aims to find an optimal jig solution for winding cone 1, which was divided into four phases, namely: research, design, machining and implementation. The research phase included the study of the old jig, as well as other solutions already developed by other authors. The design phase was based on the Design for Six Sigma (DFSS) methodology for the fixture. Various iterations of the jig components were designed, assembled and tested using Solidworks CAD model. The critical outcomes of the project were harvested from the implementation phase. The modular jig was able to machine 12 parts per cycle, proving to increase the number of parts machined per day by 32%, with expected savings of more than €6000 per year in machining cost. The added benefit of a modular jig system was that one base (skeleton of the jig) could be used in machining different products. Minder weergeven