Process Improvement for Drill Bit Blanks For MN Twist Drill

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Process Improvement for Drill Bit BlanksFor MN
Twist Drill
University of Minnesota Duluth
Department of Mechanical and Industrial
Engineering

• The Three Orienteers
• Scott Anderson Project Leader
• Andy Johnson Mechanical Engineer
• Tony Niemczyk Industrial Engineer

Report Number UMDMIE-CD-2006WPDK12
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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

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Problem Statement
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Scope of Project

• Orientate drill bit blanks from cut-off machine
• Directly feed blanks into coning machine
• Increase throughput
• Reduce work in progress

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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

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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

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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

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Final Design Concept Chute Hopper
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Mechanisms
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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

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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 plates

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PLC Flowchart
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Setup Improvements

• A standard process for setup would be very
  beneficial to process flow
• Identify external operations
• Identify internal operations

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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 professors
  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

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MN Twist Drill

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• Comments