Damian AshmeadDamian Ashmead
Adam BinkleyAdam Binkley
Angela HuenerfauthAngela Huenerfauth
Beth MillerBeth Miller
Jonathan RashidiJonathan Rashidi
Ion Selective Paste DispenserIon Selective Paste DispenserCurrent Dispense Process
- Laser Scan to Measure Electrode Elevation
- Dispense Paste using Stitch Pattern Onto Electrode
- Move to Next Laser Read Location
Apparent Design Flaws• Stitch Pattern• Excess Movement• Human Interaction• Outdated Control Device ········
Sponsor GoalSponsor Goal
Dispense Machine is the bottle-neck in the Dispense Machine is the bottle-neck in the electrolyte test cartridge production line.electrolyte test cartridge production line.
Increase productivity of paste dispense Increase productivity of paste dispense process. process.
Project FocusProject Focus
Developed Top 5 Wants->MetricsDeveloped Top 5 Wants->Metrics Productivity – Manufacture RateProductivity – Manufacture Rate Simplicity – Minimal Hardware ChangesSimplicity – Minimal Hardware Changes Paste Quality – Stay Within Existing TolerancesPaste Quality – Stay Within Existing Tolerances Low Cost - $Low Cost - $ Accuracy – Number of Paste Lines Within TolerancesAccuracy – Number of Paste Lines Within Tolerances
InvestigationInvestigation Record Video Footage of Existing ProcessRecord Video Footage of Existing Process Analyze Time BreakdownAnalyze Time Breakdown
Process Time BreakdownProcess Time Breakdown
Time Percentage of Actions During Paste-Dispense Process
13%
13%
5%
67%
2%
Arm Moves to Sensor
Sensor Read
Arm Moves to Thread Loci
Stitching
Other
Process Time BreakdownProcess Time Breakdown
Concept SelectionConcept Selection
Based Upon the Time BreakdownBased Upon the Time Breakdown Total Time ~ 218 secondsTotal Time ~ 218 seconds
Areas of Focus:Areas of Focus: Paste Stitch Time ~ 146 seconds (67%)Paste Stitch Time ~ 146 seconds (67%) Laser Reads ~ 38 seconds (18%)Laser Reads ~ 38 seconds (18%)
Initial ConceptsInitial Concepts More dispense apparatusesMore dispense apparatuses Use dispense manifoldUse dispense manifold Alter dispense methodAlter dispense method Altering laser read processAltering laser read process Buy new dispense machine Buy new dispense machine
Concept Selection - BenchmarksConcept Selection - Benchmarks
• Both Show Potential for Faster Dispense Methods
• Both Show Minimal or More Advanced Laser Scans
I&J Fisnar Inc. http://www.ijfisnar.com/usa/movies.asp
Project ComponentsProject Components
Project Scope Broken Down Into 2 Parts.
Maximize Speed and Accuracy For Both Parts
Increase Process Capacity
Part #1Alter Dispense
Method
Part #2Decrease Number
Of Laser Reads
Part #1 - Dispense MethodPart #1 - Dispense Method
Reduce Dispense Time - 16 lines of pasteReduce Dispense Time - 16 lines of paste 5 seconds per line currently5 seconds per line currently Increase speed while maintaining accuracyIncrease speed while maintaining accuracy
How Will We Accomplish This?How Will We Accomplish This? Develop new paste dispense methods using offline Develop new paste dispense methods using offline
test device.test device.““Toothpaste” methodToothpaste” method
ValidationValidation Time – Video FootageTime – Video Footage Accuracy – Light MicroscopeAccuracy – Light Microscope
•••••••••
Offline Test DeviceOffline Test Device
Time ResultsTime Results
““Toothpaste” Method – 1.4s per electrodeToothpaste” Method – 1.4s per electrode
Accuracy ResultsAccuracy ResultsTolerances: 0.024” to 0.036”Tolerances: 0.024” to 0.036”
Paste Lines Examined with Light MicroscopePaste Lines Examined with Light Microscope Max Width – 0.029” Min Width – 0.026”Max Width – 0.029” Min Width – 0.026”
Part #2 – Decrease Laser ReadsPart #2 – Decrease Laser Reads
Decrease Laser Read TimeDecrease Laser Read Time Reduce Number of Laser ReadsReduce Number of Laser Reads
How will we accomplish this?How will we accomplish this? Prove electrodes are at same heightProve electrodes are at same height
Hold ceramic plates flat under vacuumHold ceramic plates flat under vacuum
Scan electrodes using CCM laser scannerScan electrodes using CCM laser scanner
Analyze data to show electrodes are at consistent Analyze data to show electrodes are at consistent elevationelevation
Vacuum Plate DesignVacuum Plate Design
Current Design•Square Design
• Vacuum Area ~ 4in2
• 0.25” Thick Vacuum Channel
Experimental Design• Circular Design
•Vacuum Area ~ 6.75in2
• 0.03125” Thick Vacuum Channel
CCM Laser Scan Test CCM Laser Scan Test
.
.
• Collect Plates from Variety of Batches• Good Test-bed
• Hold Plates in Same Position• Assures Accurate Repeatable Data Collection
• Scan Individual Rows of Electrodes • Compare Electrode Elevation
Variables
1. Vacuum Plate2. Batch Numbers
Data from multiple scans of single line were averaged. Data from multiple scans of single line were averaged.
Electrodes located from graph of data.Electrodes located from graph of data.
Heights averaged over each Heights averaged over each
electrode in line (Six per line).electrode in line (Six per line).
Difference was calculated Difference was calculated
between maximum and between maximum and
minimum electrode height on minimum electrode height on
plate. plate.
Laser Scan Data AnalysisLaser Scan Data Analysis
-3.085
-3.080
-3.075
-3.070
20 40 60 80
Laser Scan ResultsLaser Scan ResultsElectrode Elevation Data Electrode Elevation Data
Variation using current vacuum plate: 0.0015”Variation using current vacuum plate: 0.0015”
Variation using experimental vacuum plate: 0.0010”Variation using experimental vacuum plate: 0.0010”
0.1238
0.124
0.1242
0.1244
0.1246
0.1248
0.125
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
Electrode Elevations Over Single Plate
0.001 in
Electrodes
Ele
va
tio
n (
in)
Time Reduction AnalysisTime Reduction Analysis
218s
170s
124s
Prototype / Experiment CostPrototype / Experiment Cost
Offline Test DeviceOffline Test Device $110$110Hardware $60Hardware $60
Aluminum MIC-6 $50Aluminum MIC-6 $50
Aluminum Vacuum PlatesAluminum Vacuum Plates $100$100Vacuum PlatesVacuum Plates
Total CostTotal Cost $210 $210
Process SummaryProcess Summary
Dispense MethodDispense Method Decrease Dispense TimeDecrease Dispense Time Maintain AccuracyMaintain Accuracy
Laser ReadsLaser Reads Decrease Laser ReadsDecrease Laser Reads ACCOMPLISHEDACCOMPLISHED
ACCOMPLISHEDACCOMPLISHEDACCOMPLISHEDACCOMPLISHED
ImplementationImplementation
“ “Toothpaste” Dispense MethodToothpaste” Dispense Method Software Engineer – alter control code Software Engineer – alter control code
Replace vacuum plate with new plate Replace vacuum plate with new plate designdesign Decrease laser reads to 1 per plateDecrease laser reads to 1 per plate Software Engineer - alter control codeSoftware Engineer - alter control code
Conduct further calibrations and on-line Conduct further calibrations and on-line teststests2-3 months, $20,000 – $30,000 2-3 months, $20,000 – $30,000
Questions?Questions?