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Process Improvement for Drill Bit Blanks
For MN Twist Drill
The Three OrienteersScott Anderson – Project LeaderAndy Johnson – Mechanical EngineerTony Niemczyk – Industrial Engineer
Department of Mechanical and Industrial Engineering
University of Minnesota Duluth
Report Number UMDMIE-CD-2006WPDK12
Problem Statement
• Blanks are coming off of machine without orientation
• Manually sorted to bins
• Blanks manually moved approximately 10 feet to coning machine
• Manually loaded into coning machine
Problem Statement
Scope of Project
• Orientate drill bit blanks from cut-off machine
• Directly feed blanks into coning machine
• Increase throughput• Reduce work in progress
Functional Requirements
• Require little maintenance, less then $2,000/year• Reduces manual handling labor• Simple in design • Utilizes gravity as much as possible• Maintains or improves throughput • Adaptable to varying lengths and diameters• Efficient• Implemented with little risk due to offline testing
Constraints & Limitations
• The speed of the cutting and coning machines which for the cuttingmachine is 200 parts per minute
• Budget is a 2 year payback on a $20,000 a year salary based on the reallocation of labor
• Material type being cut which includes cobalt and various types of steel.
• Drill bit diameter and length varying from 1/4” to 1/2” and 2 ½” to 6” respectively
Final Design Concept Chute & Hopper
• Blanks orientate on vibratory table and slide down channels to coning hopper
• Coning hopper uses rake mechanism• Logic senses when blanks are in hopper
waiting to be fed into coning machine
Final Design Concept Chute & Hopper
Mechanisms
Economics
• Installed Cost: $10,297.55 • Annual Benefits of:
– System by itself: $37,070.00 – System with reduced setup time: $747,070.00
• Annual Maintenance (10% of installed cost): $1,029.76
• Payback Period of:– System by itself: 108 working days– System with reduced setup time: 5 working days
Procedures
• Programmable Logic Controller Procedure– Sensors in the system check the system for
out of control circumstances
– Ensure that the hoppers never overflow with material
– Determine the operation of the slider platesInputs Outputs
Sensor in coning hopper to detect height Turn off vibratory motor
Sensors in coning hopper to move plates Move plates in and out to prevent damage to coning belt
Sensor in Vibratory hopper to detect height Turn off conveyor
Pushbutton to determine if setup is happening Sensors are not used until pushed
PLC Flowchart
No
Setup
EnableSensors
All SensorsDisabled
Yes NO
TMRPart In top of
Vibratory HopperYes
Part?
TMR
Yes
Part?
Turn offConveyor
Yes
No
No
No
TMRPart In top of
Conning HopperYes
Part?
TMR
Yes
Part?
Turn offVibratory
Motor
Yes
No
No
TMR
Part In ConningHopper
Yes
Part?
TMR
Yes
Part?
Move Plate
Yes
No
No
No
Setup Improvements
• A standard process for setup would be very beneficial to process flow
• Identify external operations
• Identify internal operations
Acknowledgments
• We would like to thank Matt Mattson for contacting the University of Minnesota Duluth with a senior design project and for accommodating all of the needs of the group in a respectful and timely manner
• We would like to thank Scott Allison for giving Matt Mattson the capabilities to go to the University and finance the project
• Finally we would like to thank our professor’s Dave Keranen and Bill Pedersen for all of their help and advice in the development of the project and for guiding us to not only get the project to completion, but also in a manner to help us learn new skills on our own
MN Twist Drill
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