Maximizing Output: Robot Saves 10 Man-Hours Each Week Cutting 1000 Tubes Daily! | JJB Lean Academy
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- เผยแพร่เมื่อ 9 ก.ค. 2024
- I forgot to include a version of this Improvement see it here : • Arduino Controlled Tub...
In this video, you will see a process that was once lengthy and time-consuming, now fully automated using our Nukeson HanBot Robot. By using this technology, it is now possible to produce 1000 tubes per day while saving 10 man-hours every week. It has taken us 7 years to arrive at this point, and we are excited to see where it will be in another 7. We hope that this video will inspire you to identify areas of waste in your own processes.
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#EfficiencyEvolution #ContinuousImprovements #SweepSortStandardise #RobotAutomation #TimeSaver
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If a piece of equipment will pay for itself within 3 years we go for it. With this it was a learning experience for us too, now we are able to offer cobots as a new product based of our own testing and implementation, we have one of these welding too😊
The Robot arm is really cool, but I can't imagine the initial design, production, machinery, would ever get paid off. The man hours alone for design and trouble shooting would be way more than just having a labourer working. This is why you don't see production like this even in China, where they would be making 10s of millions of the same part... its just never worth it versus "unskilled" labour.
@@Stevieboy7 it took me 2 weeks to design and build, it was a learning experience, really we didn't need to fully automate it. But wanted to learn it's been a fantastic learning project for me! And relieved a employee of a boring task 😊🙏
Hope the robot lasts longer than 3 years then. Maybe 4 since there is maintenance and operating costs to consider as well.
@@christiantosumbung5791oh yeah we’ve had joints go out on universal cobots and they’re not cheap to replace
I feel the full robot arm is a bit over kill here. But if it was also for learning how to use the arm then I see the value there too.
LOVE the cowbell...
Who says that engineers DON'T have a weird sense of humor???
I don't think anyone has ever said that to be honest.
Haha when i saw the cowbell, i was totally sold!
I did robotics, control systems & special machines for 35 years and think you've done a fantastic job there!
Thanks Dave! 😎🙏
I work in industry and I’m just pleased to see someone who actually thinks seriously about automating a process . Well done .
Thanks David 👍👍😊
I have a weird passion for automation. I think I finally found my favourite youtube channel.
We too! I wish I had more time to automate more things 😁😎
Cowbell is an amazing touch! Great system!
The cow bell is the icing on top. Wonderful
Thanks 😁😁🙏
god that's a beautiful solution! The mid-point of automation was amazingly old-school, but being able to integrate that cobot to simplify the whole setup AND do a one piece flow is such a brilliant setup.
Thanks so much 😊😊 it's was a fun project too!
what a great project. The bell part was fun and I would never replace it for a traditional alarm.
Jack you are seriously a genius and a true inspiration!!
Jack❤ thanks for making this video to show this improvement evolution! I think I requested it some time ago and I LOVE IT. Really shows the improvement progress and all the SMALL STEPS that are actually required to go to where you are right now! Thanks again!
Glad you liked it!! Thanks Lucas
Outstanding improvement, Jack. Thanks for taking us through the evolution of this process. Honestly, I was already impressed with what you had done BEFORE you even introduced the cobot!
Thanks Norm! 😊
Best lean video I’ve seen in a long time !! Well done Jack and team!!
Thanks Ryan! You we're a big part in getting our journey started, showing us what's possible 😊
This machine sparks joy. So good.
Haha, that cow bell is gold. (Until it picks up your favorite hamster instead).
That bell was hilarious!
more of these videos please. its awesome jack!
"They took our jobs" - thanks for sharing journey workflow
My pleasure!
Fantastic, the cow bell is the best !
All of that is absolutely brilliant!!
Thank you 👍👍😎
Jack I am so inspired, fantastic!
Who knew paper towel tubes would be such an in demand product.
Brilliant vid thanks, I'm a one man band manufacturing in UK too.
New sub.
This is outstanding!! I love seeing your evolution to improving your “processes”.
Thank you for your support 😁😊
This cowbell is cherry on the top :-)
Love it. When I faced a similar challenge I learned about 3d designing and injection molding. ;-)
Do you have a video?
Fantastic integration! So awesome to see these complex tasks being automated. I look forward to a world full of robotic arms and humanoids wherever necessary.
Exactly! Me too 😎👍👍
Absolutely love it!
This is very clever. I like it!
Thank you!
Fantastic work!! Congratulations!!!
Thanks for sharing. I will order your blue roll dispenser soon!
Super Interesting ! ! !
the cowbell is hilarious!
That’s awesome mate. Love your work
Thank you!
This is another level of coolness.
Thanks so much 😎😎
Wow, thats an amazing and easy to understand Piece of Automation. My Question is, at least what I noticed, the magazine for the PVC Tubes is the main restriction when it comes to human service intervalls by restocking the Tubes. As someone who works for a CNC Machine Manufacturer, we also build a kind of Hopper where round Materials can be loaded in and get dropped out one by one. So depending on the Size of the Hopper, there can easily be stored more than 17 Tubes, so if there would be stored 34 Tubes and dispensed by an Arduino that is connected to a colour or capacitve Sensor it would double the Human service intervall and would let the automation run over night if the hopper is big enough. But the Machine in total is an awesome development and showing the development step by step is awesome.
Thanks for comment, so I'd love to make a hopper for it, but wanted to keep it simple to start with, my time is limited to do it because I have a business to run, currently we are very happy with the result
Thats just soooooo cooooool! :)
Thank you
Stunning
"I gotta fever .... and the only prescription ..... is more cowbell!" -Christopher Walken. (Amazing setup and it's fun to watch! Nice job!)
Thanks so much 😁😎
That’s great. I love the idea.
Thanks!
Very cool video. I don't work in manufacturing at all, it's just pleasing to see the progress you've made in automating around this same product.
Thanks for the positive comment! 😊👍👍
I also build automatic machines and really like your automated process! Thanks for sharing your projects!
Thank you 🙏😎
Great story of lean Jack!
Fantastic!
Thanks 😎👍👍
Making setups like this is a dream, so inspired
It's really really enjoyable, it's almost like playing around rather than work!
Very clever indeed !
Absolutely love it!!
Glad you like it!
You are brilliant!!
Thank you 🙏☺️
This looks like so much fun. One of the reasons I relish software engineering is the ability to solve issues through automation.
Yes it was such a fun project ☺️😎
I love this!
Amazing video Jack! 👏🏻
Glad you enjoyed it!
This is one of the many things I really miss about being in business. Looking back I think I got more of a kick out of the R & D, continue improvement, working more "on the business" than actually working "in it" I love manufacturing but sadly with it's demise these days it's getting harder & harder to have a go! I guess I just need to find that one unique thing that people need to have even a chance of getting back to it (I simply HATE working for a boss!) A great video, I get there would have been lots of hard work & failures to get to that point, so well done!! 👍
Thanks for you positive comments! What you say is 100% correct, it's so enjoyable doing the r & d. I could spend a year tuning this cobot cell, it's endless the amount of improvements that could be done. There's millions of products out there that require this type of thing they just need to be found
That cowbell!!!!
I absolutely love this video. I use a tun of pneumatics and learned to code on Arduino to incorporate automation into my factory as well. A real game changer. Respect for this video.
*edit* just saw the cow bell. hahahah, this guy is awesome!
Oh wow cool! I learned on arduino too it's so much fun, would love help, make some videos too!
Love bell idea. Great job 👏
Thank you! 🤗
Nice work. I have one of those blue roll holders, it`s great. Obviously a pre robot model.
Very cool!
Love the cowbell! We need more cowbell.
Instead of the robot picking up the tube and pushing it through each time before having to reach over and grab the cutoff piece, you should have it set up to drop a full pipe in place, then some grab rollers could push the pipe forward until it breaks a beam at the correct length. Just a thought.
I kinda wanted to do that, but really wanted to keep it simple and use the cobot as much as possible. It produces more than we require currently 😎
@@JackBusseyUK I get it. Just my ADHD mind over-thinking. LOL Great work though.
@@dgoddard haha yes likewise my mind went wild on this project, I didn't have much spare time to work on it so had to keep it simple 😁
Love the cow bell
Nice! I liked how you learned a new skillset in order to upgrade and improve your production method!
Thanks Ken! 🙏👍
Nice alarm system :)
And then the next step, including batch processing into this setup :D
Next step I've not worked that out yet
Love the automation you have done on this so interesting, next step a +Z laser engraver with a -Z laser engrave, takt time will increase by nearly 8s :)
Yes great idea
This is uber cool, now I want to see it run at full speed!.
Great job!
Thanks!
Those robots are pretty decent, (Hanbot is a fun twist on the supplier's name) had some time working with the manufacturer of them 4 years back, they've improved a fair bit since then from the look of it. Really awesome setup you got there! Nice job! Little bit concerned about the laser engraver without a proper enclosure. They can definitely seriously blind you, and even damage your eyes from the reflection. I've done a fair bit of work with MOPA / Fibre lasers. They're no joke. Without enclosure they are far into a class 4 laser. I see a lot of videos not treading them with the respect needed, especially from Overseas manufacturers. You only have one set of eyes!
Thanks for you comments! Glad to see you like it 😎😁 did you notice the 3d printed laser shield it stops any laser light getting out, do you think this is not enough?
very cool!
Awesome!
Glad you think so!
nice end effector.
Love the cowbell
Thanks 😎😎😁
LOVE this automation.
However, if you change the design you remove 75% of the steps and two loose parts...
Instead of open sides for the pipe, close those side faces and make three U-shape cuts in each side, then bend in the "tabs" that are created. The shorter PVC would then be contained and vertically supported by the bent tabs, and wouldn't need branded end caps installed to limit side-to-side motion. Saves material also.
Thanks! That's a great idea, maybe I'll use that for next version 👍👍💡
Bravo sir, Bravo. 👏 I love see someone always trying to figure out a way to do something better in a world of complainers. The bell was a great touch. Would love to know how you sourced parts, the robot, the software, how you learned to program it. Just came across this one video so maybe there are more…good job!
Thanks for the positive comment! The cobot has a touch screen controller which I learned to program it actually doing this machine, it was actually quite easy to do, trial and error with lots of small Improvements, overall it took a couple of weeks to build it.
I'd love to see how you built the cutting and capping machines before you got the robot
Thanks for the idea!
We need more cowbell!
The cow bell is the most important part of this whole operation.
Thanks 😎😎
I allways try to explain to people who are scared of AI an example of using robotics in the industry. This is a nice easy example to show.
Thank you
Wow!
That's awesome. Any reason you cant make the capping machine add both end caps at once?
I could but would require lots of work to achieve, so I kept it simple
Very nice!! thank you for sharing. incredible upgrade. Are these fiber lasers UV? The cowbell is the nicest touch.
Thanks for your comment 😊 the fibre laser marking machine is not UV
Great video!!
Thank you
That's so cool man, thank you for sharing! I love manufacturing. Just curious what is that arm you're using and how much do those go for?
Thanks! Approximately 25k
Man got some skills
Thanks 😁😁👍
very inspiring
Thank you 😎🙏
I LOVE THE COWBELL!!!! That is such a fun way to alert, and also incorporates strong audio controls around. So fun! What did the whole setup cost?
Really really fun! 😁 Approximately 30k
so nice！！！
I noticed in the capping part can you install the cap inserters on both sides so it would be done at once ?
It would need lots of work to make that happen so went for a simple option
That’s amazing . What are you using to control the cobot ?
It comes with a control system which is super easy to program
This is mesmerizing! Love all the custom machines. Have you considered heating and then flaring or beading the ends of the tubes? Would eliminate end caps altogether...
Yes I thought about it and actually tested it with a heat gun, I couldn't get it to look nice, so stayed with the cap design
@@JackBusseyUK fair enough. I figured you would have, you are always optimizing. But doesn't matter how optimized things are, if they're ugly people don't buy them. Keep up the great work. Thanks for sharing!
Amazing. Love the cow bell too.
How fast can you dial it up speed wise? Also, I’d be super interested in a video on how you programmed it. Cheers
It's pretty much at max speed in the video, I plan a programming video so people can see how easy it is
Great Work, love to see this sort of innovation in British manufacturing. Ignore the naysayers, I think looking at the naysayers most of us want to go back in time to the age of manual lathes. They ignore the fact that finding and employing people to do this type of work is extremely difficult. Have you tried any other brands of Cobot?
Thanks! I do doubt that the naysayers are washing their clothes in a local stream 😂😂😁 Yes I invested around 200k, testing lots of different brands, we now are UK and Europe distributors for this one 😎🇬🇧
need more cow bell.
More Cowbell!!
i love the bell
That looks great, must be a lot of fun to work out this process!
I wonder, is the robot not very slow at its task? Can you produce the same amount of tubes in a day as you were doing before? Or did you not have to run at full capacity?
It was definitely fun to work out the process and build / program it! It's speed suits our demand perfectly, if anything we can produce more than we require.
"Save my people, make their job easier" - and that's how we do business !
I am going to steal your idea for the cow bell. This is the best idea to improve happiness on the work place 😁
The only thing I was wondering about was how you get the end-caps in the machine but I just noticed a piece of conduit on the wall. I am guessing this connects to a vibration sorter, similar to the one being used in the old setup.
Glad you liked it!! So the cap tube is currently filled manually, I'm working on a automated process 😁👍
Mate what an amazing production line well done did you work this all out on your own or did you have a consultant help make this?
Thanks! I worked this out on my own, took each step as I went, surprisingly it was quite easy to do, although took a couple of weeks
@@JackBusseyUKwell it’s very impressive, you should feel very proud.
I’m currently building a production line making expansion joints for industrial cement floors in Brazil and you really inspire me to keep pushing though the inefficiencies for solutions.
thank you for the motivation 🙏💪
@@jodyqt thanks! Yes never give up and continue to improve every day!
Need more people like you in British business. So many British businesses are absolutely allergic to R&D and would rather import some randomer from the third world and pay them peanuts to do that job. It's why our productivity in this country is such dogshit. That said, I think the robot arm is overkill. Most companies wouldn't even bother with your first round of automation even!
It's sad because many businesses are not trying to improve processes, we try to improve everything to make the work easier and better quality for the customer.
I love the no eye protection around the fiber laser lol
On the robot version we have greatly improved this, with the 3d printed shroud
@@JackBusseyUK Much improved. The fume extractor is a nice feature. Venting it outside might be even better unless that gets you into regulatory purgatory. PVC (if that's what the caps are) gives off HCl when burned. Thanks for the video.
Thanks for sharing this! Great thought process and execution. Instant Like, Subscribe and Notifications from me.
Glad You enjoyed it! Thankyou for joining our journey!
My Mannnn
Thanks 👌👍👍