General description

While production methods are diversifying from mass production to high-mix low-volume production and one-piece flow production, the cleaning processes in the precision machining lines also need to be adjusted accordingly.This volume describes the precautions for switching the cleaning method from the existing lot-by-lot process to that designed for high-mix low-volume production or one-piece flow production.

Explanation

To automate the cleaning process for high-mix low-volume production or one-piece flow production, the following specifications are required for the equipment:

Requirements-1. The equipment must be designed in the specifications (appropriate size, capacity, etc.) eliminating inefficiency.

・For the mass-production batch manufacturing system using large machine tools, the batch processing by a large washing machine was also adopted for the cleaning process (Fig.1). For the high-mix low-volume production, the washing machine should be smaller and adjusted for smaller lots (Fig.2).
・For the one-piece flow production and the cellular manufacturing system, the goods are processed in synchronization with the previous process and the subsequent process (in the same pitch.) Therefore, such tasks must be performed in the optimum environment and the equipment should be designed in the specifications (appropriate size, capacity, etc.) eliminating inefficiency.In other words, small machine tools instead of the large-sized ones are used in these methods; the machining work itself will also be different.This means that the cleaning process should be adjusted accordingly, such as adopting a small washer, so that the machine operators can clean the products whenever they have done with the other tasks.

Requirements-2. Appropriate cleaning solution and conditions must be selected to work better with smaller lots.

・Since various types of solvents are included in the machining fluids, such as cutting fluid and grinding lubricant, insufficient cleaning conditions or drying conditions may result in dry stains or cause the products to corrode after reacting with the materials.The cleaning conditions designed for large washers will not work. When adopting a simplified cleaning method, it is necessary to select preliminary cleaning solution and cleaning conditions once again.