Streamlining Production: ECRS Approach to Enhancing Efficiency in Case Tank Sub Weld of Hydraulic Excavator

Abstract

This research aimed to reduce the production time in the manufacturing process of fuel tanks, with a focus on enhancing the efficiency of the process to better meet customer demands. A study of the production process revealed that the primary issue was in the welding stage at the top of the tank using a robot, which took 2 hours and 45 minutes. Almost half (1 hour 22 minutes) of the time were spent on setting the position of the workpiece— a step that must be repeated each time a new workpiece was introduced. This significantly contributed to reducing throughput and increasing labor costs. To address this issue, the research team applied the ECRS concept to analyze and streamline the production process by eliminating unnecessary steps. Consequently, the team designed and developed a workpiece holding fixture to assist in the welding process. This fixture ensured the workpiece was positioned accurately without the need for repeated setup. Two conceptual designs of the fixture were initially developed and evaluated using FEA. After evaluation by engineers and welding staff, using AHP, the best option was determined. As a result of this improvement, cycle time in robotic welding was reduced to 1 hour and 23 minutes a 49.26% reduction.