power partners, inc de-mold pokayoke. © 2015 power partners, inc t:706.548.3121 process overview...
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Power Partners, Inc
De-mold Pokayoke
© 2015 Power Partners, Inc T:706.548.3121 www.PowerPartners-usa.com
Process Overview
• Power Partners in Athens, GA makes transformers
• Transformers utilize coils of conductor that are wound around aluminum molds
• After the coils are wound, the molds must be pressed out to make room to insert the cores
MoldsMolds
Cores go here after tooling is removed
© 2015 Power Partners, Inc T:706.548.3121 www.PowerPartners-usa.com
Process Overview (continued)
• To remove the tooling, coils are slid onto this arbor
• Parts of the arbor expand to clamp the coil in place
• Rods extend out just above and below the arbor to press tooling out
© 2015 Power Partners, Inc T:706.548.3121 www.PowerPartners-usa.com
Before State• After the top and bottom
tooling is removed, the coil drops and rests on top of the arbor until removed
• On occasion, an operator would become distracted and start the machine before removing the coil
• This would cause the rod to drive into the coil ruining it
© 2015 Power Partners, Inc T:706.548.3121 www.PowerPartners-usa.com
Pokayoke Idea • A raised “rail” was added
to the center of the arbor on each side
• The mold plates had a groove cut to match the rail in the Arbor
• With the new design, the coil now suspends itself after the top/bottom material was removed
© 2015 Power Partners, Inc T:706.548.3121 www.PowerPartners-usa.com
Pokayoke Effect• Now, if the machine is
accidentally cycled again the rods simply glide past the coils where the molds were previously
• This makes it impossible to damage the coil by striking it with the rods
• All work was done in house by our Maintenance Team and one of our Process Engineers
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