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Automated Manufacturing and Interval Inspection

Good Morning,

I would like some opinions on this subject. We have implemented some automated robotic machining cells these past few years. The idea was to use really good tooling that would last all day before chipping or breaking and use robots to load/unload the CNC machines. We've been mostly successful but not fully automated. The CNC operator has to setup the machine every morning, replace inserts and tools and run full inspections on a CMM before releasing the robot for the day. The the cell run all night and we come in the morning to full carts of parts.

We never got to the phase where the robot would load and unload any CMM like the whole industry 4.0 cycle. Its a a bummer for me because I was interested in learning that side of automation.

What was done was they basically stop inspecting every part and started checking every 5 parts or whatever interval. The company is considering more automation project but I think the idea make parts good in the first place with the intent of not checking every single part off that line.

Is this level of automation and inspection something common or is this still considered "new" way of doing things? Should I be doing random full inspection audits?
Parents
  • * What is "good tooling that would last all day before chipping or breaking"?

    We used tooling that lasted more than a day and was actually REALLY good tooling made by an industry leader in that sector. DM me for more details.

    * What are some details on "We've been mostly successful but not fully automate"?

    This wasn't an easy task for us, but thankfully we got to a place where we called it a "success" though I know that means different things to different people.

    * What do you mean by this, does the robot not load parts on the CMM? "We never got to the phase where the robot would load and unload any CMM like the whole industry 4.0 cycle. Its a a bummer for me because I was interested in learning that side of automation."

    Our robot loads/unloads parts to a number of different stations all day long/night... the only time humans enter the equation is when parts are finished and are pulled from stock/storage locations.

    * We struggled to figure out our inspection intervals in the beginning but then settled on having different intervals for each part as no part was the same. "What was done was they basically stop inspecting every part and started checking every 5 parts or whatever interval."

    * I came to find out from word to mouth that it is more common than I initially thought and that most folks don't go around talking much about it. "Is this level of automation and inspection something common or is this still considered "new" way of doing things? Should I be doing random full inspection audits?"

    Some background.
    I landed a gig where the CMM was part of an automations cell. Due to reasons I won't disclose here I got the opportunity to 'learn' the entire cell while I wasn't doing CMM things. I learned it all and eventually left the company to pursue a career in control automation. I've been doing it for about a couple years and can finally say I can build you a fully autonomous CNC tending cell (with some help of a small team of course as I'm not ME, EE, etc.).

    DM me and we can chat in more detail about this topic if you're interested.
Reply
  • * What is "good tooling that would last all day before chipping or breaking"?

    We used tooling that lasted more than a day and was actually REALLY good tooling made by an industry leader in that sector. DM me for more details.

    * What are some details on "We've been mostly successful but not fully automate"?

    This wasn't an easy task for us, but thankfully we got to a place where we called it a "success" though I know that means different things to different people.

    * What do you mean by this, does the robot not load parts on the CMM? "We never got to the phase where the robot would load and unload any CMM like the whole industry 4.0 cycle. Its a a bummer for me because I was interested in learning that side of automation."

    Our robot loads/unloads parts to a number of different stations all day long/night... the only time humans enter the equation is when parts are finished and are pulled from stock/storage locations.

    * We struggled to figure out our inspection intervals in the beginning but then settled on having different intervals for each part as no part was the same. "What was done was they basically stop inspecting every part and started checking every 5 parts or whatever interval."

    * I came to find out from word to mouth that it is more common than I initially thought and that most folks don't go around talking much about it. "Is this level of automation and inspection something common or is this still considered "new" way of doing things? Should I be doing random full inspection audits?"

    Some background.
    I landed a gig where the CMM was part of an automations cell. Due to reasons I won't disclose here I got the opportunity to 'learn' the entire cell while I wasn't doing CMM things. I learned it all and eventually left the company to pursue a career in control automation. I've been doing it for about a couple years and can finally say I can build you a fully autonomous CNC tending cell (with some help of a small team of course as I'm not ME, EE, etc.).

    DM me and we can chat in more detail about this topic if you're interested.
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