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Sherlock Ohms

Robot Servo Errors Were Only Human

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GlennA
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Gold
Re: Data
GlennA   8/2/2012 10:43:02 PM
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Ralphy Boy;  The part tracking was not changed.  The 'G' van was phased out about 2 years later, so no significant process improvements were planned or implemented.

One of the reasons that robotic automation improves quality, is robots will not work with 'junk'.  A human welder can adjust the fit of a bad part and then weld the assembly.  The robot welds where the part was supposed to be, and the assembly then fails.

Ralphy Boy
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Platinum
Re: Data
Ralphy Boy   8/3/2012 12:33:09 AM
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"The cross rails were different according to the gasoline tank size. If the cross rails installed did not match the build data, the selected robot path could crash the spot welding gun into the cross rails."

Actually when I said crash I was thinking of this. I'm not sure about the robots on the GM line but ours don't always do well recovering from a crash...

We do that assembly line sharing stuff at times too... When a multiple use line is running, maintaining a clean separation between the small stuff, like optionals can be tough. I am not saying we do it perfectly, but we do strive to learn and improve. ; )

And I get what you're saying about quality. Robots are amazing at repeating the same process over and over in a very precise way (fast too the little buggers).

Tool_maker
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Platinum
Re: Only half the automation was completed...
Tool_maker   8/3/2012 6:32:19 AM
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@kfqd: I have never worked in the sort of environment described so this question may be silly. If the operator can manually select the wrong part, is it not possible that another operator could apply the wrong tag/code?

GlennA
User Rank
Gold
Re: Only half the automation was completed...
GlennA   8/3/2012 4:50:03 PM
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Tool_maker;  I'm guessing you mean a tag applied to the part.  For most of the parts, the part itself was not individually identified by a tag or code.  Only the bin or box containing the parts had an identifying code.

There were several cross rails, and it could be a case of two cross rails in the wrong sequence - the parts were correct, but in swapped locations.  In other cases it could be an extra, unnecessary part added.

When the operator at the station where the frame was mated to the floor identified an actual build vs. build data mismatch, an electrician could edit the PLC bit data to correct the build data in the PLC.

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