[Case Study] Eliminating Losses During Line Changeovers
Various losses occur during the changeover on a line that handles multiple varieties! Here is a case study on how we improved monetary losses in about 13 operational days!
We have adopted the "Kanban production system" and produce 15 varieties of products on one line, but on busy days, up to 8 "changeovers" are required. After recording the changeovers on video and analyzing the situation, it was found that the "overall equipment efficiency" and "net operating rate" were declining. Therefore, we held discussions with the maintenance design team and automated the changeover process. We installed Makome Research Institute's linear encoders "SIE-140 (incremental)" and "SAE-200 (absolute)" on the motor-driven thickness adjustment machine. As a result of the improvements, the operating time rate increased, and changeover losses were transformed into production that generates revenue. The initial investment was 4,852,600 yen, but the cost-effectiveness improved the monetary loss in about 13 operating days. *For more details, please refer to the PDF document or feel free to contact us.
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**Case Summary (Partial)** ■Trouble Case - During stage changes, "machine height adjustments" and "width adjustment losses" occur due to changes in work type. ■Trouble Situation and Losses - Stage change frequency: 5 times/28,800 seconds - Line stoppage loss: 385,500 yen/day - Annual line stoppage loss: 92,520,000 yen ■Points of Improvement and Expected Customer Benefits - With a resolution of 0.1 to 0.025mm and repeatability, stage changes can be done with one touch. - As it uses a magnetic encoder, it is unaffected by poor environmental conditions. - The magnetic scale operates without issues even when surrounded by non-magnetic materials (such as aluminum and stainless steel), preventing easy adjustments by on-site workers. ■Effects and Benefits of Improvement - Stage change frequency: 5 times/28,800 seconds - Stage change stoppage time: 28 seconds/1 time - Annual line stoppage loss: 1,233,360 yen *For more details, please refer to the PDF document or feel free to contact us.*
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For more details, please refer to the PDF document or feel free to contact us.
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| Model number | overview | File |
|---|---|---|
| SAS-200 | Scale Absolute |
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| SAE-200 | Head Absolute |
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Company information
Utilizing our original technology of saturable coils, we offer a fundamentally simple magnetic detection element technology that provides high precision and long-term stability even under adverse conditions. We have received strong support from a wide range of industries, including unmanned transport carts, industrial equipment, labor-saving machines, material handling, machine tools, injection molding machines, civil engineering and construction robots, food machinery, industrial machinery, nuclear facilities, and ships. We also excel in sensors for motorsports such as F1 and Moto GP, tilt meters for construction machinery, and magnetic sensors used for ultra-high precision measurements in scientific fields. Some of our products are also used in applications like multi-story parking and golf cart guidance sensors. All of our products are developed and manufactured 100% in Japan, with over 80% of our product lineup being custom-made based on individual customer requests. We have many custom options available, including waterproof, explosion-proof, heat-resistant, water-resistant, and radiation-resistant specifications. If you have any issues related to sensing or measurement, please feel free to consult us. IoT Platform: Our sales and technical staff are fully committed to addressing everything from minor customizations of existing products to proposing new detection principles. You can also rely on us for assistance with improvements. Our standard products come with a reassuring 3-year warranty. Location: Ina, Nagano Prefecture. Published on Ipros Monozukuri.
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