Optimization of the GBC 995 Auto HV Testing Machine Fixture to Enhance Part Loading, Electrode Longevity, and Productivity

PROBLEM STATEMENT

Operators faced difficulty loading parts into the GBC 995 Auto HV testing machine. The existing setup led to reduced electrode life and lower productivity due to inefficiencies in the design and operational workflow.

PROBLEM ANALYSIS

The current machine fixture design caused challenges in part loading, requiring extra effort from operators. Additionally, improper handling or frequent loading adjustments strained the electrodes, leading to faster wear and reduced machine uptime, ultimately affecting productivity.

ROOT CAUSE

The fixture design was not optimized for ergonomic and efficient part loading by operators.
Increased stress on electrodes during usage contributed to their shorter lifespan.
Delays caused by inefficient workflows reduced overall productivity.

KAIZEN IDEA

Modify the GBC 995 Auto HV testing machine fixture to enable easier part loading for operators, reduce stress on electrodes, and enhance productivity by streamlining operations.

COUNTER MEASURE

Redesign the machine fixture to improve accessibility and ease of part loading.
Implement protective measures or adjustments to reduce stress on electrodes, extending their lifespan.
Conduct trials to validate the improved fixture’s performance.
Train operators to use the updated fixture effectively and follow best practices for efficient operations.

BENCHMARK

Reduced part loading time by (Insert target percentage or time reduction).
Increase electrode lifespan by (Insert target percentage).
Improve productivity rate to (Insert target units/hour).

QUANTITATIVE

Easier part loading: Reduced operator effort leads to a more ergonomic and efficient workflow.
Longer electrode lifespan: Enhanced design reduces stress, minimizing wear and tear.
Increased productivity: Streamlined operations lead to faster testing cycles and higher output.