MANUAL ASSEMBLY WORKSHEET
1 = Part identification number
2 = Number of times that the operation is carried out consecutively
3 = Two digit manual handling code
4 = Manual handling time per part
5 = Two-digit manual insertion code
6 = Manual insertion time per part
7 = Operation time in seconds (2) x [(4)+(6)]
8 = Operation cost, centimes 0.4 x (7)
9 = Figures for the estimation of the theoretical minimum number of parts
_1 2 _3
___4 _5 ___6
_____7 ___8 9
23 1 30
01.95 00 01.5
003.45 01.38 1
PICK UP TOP COVER
99
12.0 012.00 03.00
CLEAN THE TOP COVER
30 1 88
06.35 33 05.0
011.35 04.54
PEEL OFF LABEL
06 2 11
01.80
003.60
01.44 PICK CHOKE S. HOUSING
05 2 03
01.69 30 02.0
007.38 02.95
PICK UP O-RING
04 2 10
01.50 00 01.5
006.00 02.40
PICK UP CHOKE SCREW
AUTO. SCREW CHOKE
07 2 03
01.69 30 02.0
007.38 02.95
PICK UP O-RING
01 1 30
01.95 00 01.5
003.45 01.38 1
PICK UP VALVE BODY
29 2 33
02.51 40 04.5
014.02 05.60
PICK UP BLANKING PC.
01 1 98
09.00
009.00 03.60
TURN BODY UP/DOWN
2
30 01.95 31
05.0 013.90 05.56
PICK UP CH. SCREW S/A
02 1 38
03.34 43 07.5
010.84 04.34
INSERT GASKET
1
02 02.5 002.50
01.00 INSERT COVER TO BODY
19 1 10
01.50
001.50 00.60
PICK UP PISTON
18 1 10
01.50 30 02.0
003.50 01.40
INS. LIP SEAL TO PISTON
PICK UP O-RING TOOL
16 1 03
01.69 00 01.5
003.19 01.28
INSERT O-RING TO TOOL
17 1 00
01.13 30 02.0
003.13 01.25
INS. SPOOL TO O-RING
PICK UP MIDDLE O-RING
16 2 03
01.69 00 01.50
006.38 02.55
INS. O-RING TO TOOL
17 2 00
01.13 30 02.00
006.26 02.50
INS. O-RING TO SPOOL
15 3 03
01.69 44 08.50
030.57 12.23
SEAL RING TO SPOOL
24 2 10
01.50
003.00 01.20
PICK UP INDICATOR
20 2 03
01.69 30 02.00
007.38 02.95
INSERT O-RING TO IND.
22 2 30
01.95 30 02.00
007.90 03.16
INSERT ENDPIECE
09 2 10
01.50
003.00 01.20
PICK UP PISTON SLEEVE
08 4 03
01.69 30 02.00
014.76 05.90
INS. 0-RING TO SLEEVE
10 2 10
01.50 30 02.00
007.00 02.80
INS. SEAL TO SLEEVE
12 2 10
01.50 30 02.00
007.00 02.80
INS. SEAL TO PISTON
PICK UP O-RING TOOL
11 2 03
01.64 30 02.00
007.38 02.95
INS. O-RING TO SLEEVE
1
10 01.50 00
01.50 003.00
01.20 SLEEVES TO FIXTURE
14 1 00
01.13
001.13 00.45
PICK UP HALF SLEEVES
13 1 03
01.69 30 02.00
003.69
INS. 0-RING TO HALF-SLV
00 01.50 001.50
INSERT HALF PISTON
1
00 01.13
001.13
PICK UP VALVE BODY
INS. TOOL TO VLV. BODY
30 02.00 002.00
INSERT VALVE BODY
PICK UP O-RING TOOL
13 1 03
01.69 30 02.00
003.69
INS. O-RING TO TOOL
1
12 05.00 005.00
INS.
O-RING TO VALVE
1
10 01.50 30
02.00 003.50
INS. SLEEVE TO BODY
1
10 01.50 30
02.00 003.50
INS. PISTON TO SLEEVE
2
00 01.13
002.26
PICK UP END PIECE
21 2 23
02.36 43 07.50
019.72
GASKET TO ENDPIECE
2
02 02.50 005.00
ENDPIECE TO BODY
25 8 11
01.80 00 01.50
026.40
INS. COVER SCREW
8
92 05.00 040.00
16.00 FASTEN COV. SCREWS
1
98 09.00
009.00 03.60 TURN VALVE BODY
1 99
12.00
012.00
LUBRICATE VLV. BODY
PICK UP SPOOL TOOL
1
00 01.13 31
05.00 006.13
PICK UP SPOOL PIECE
PUT TOOL DOWN
26 1 00
01.13 02 02.50
003.63
INS. SPRING TO SPOOL
27 1 00
01.13 02 02.50
003.63
INS. SPRING TO SPOOL
28 1 10
01.50 02 02.50
004.00
INS. PIN TO SPRING
1
00 01.13 00
01.50 002.63
INS. VALVE TO FIXTURE
02 1 23
02.36 43 07.50
009.86
INS. GASKET TO BODY
389.22
ASSEMBLY SEQUENCE FOR THE ROBOT ASSEMBLY OF THE PNEUMATIC VALVE, WITH MANUAL ASSISTANCE
Note - Operations marked with an asterisk (*) are carried out manually.
(1) Pick up the cover (23) from the pallet and insert into fixture (32).
(2) Automatically clean the cover.
(3) Automatically feed and insert the label (30) to top cover.
*(4) Pick up the choke screw housing (6).
*(5) Pick up the O-ring seal (5) and insert onto choke screw housing.
*(6) Pick up the choke screw (4) and insert into the choke screw housing.
*(7) Fasten choke screw in choke screw housing by friction screwdriver.
*(8) Pick up O-ring seal (7) and insert into choke screw housing.
*(9) Pick up valve body (1).
*(10) Pick up gasket and assemble to valve body.
(11) Pick up valve body and insert into fixture (33).
(12) Automatically feed and insert the blanking piece (29) into the valve body.
(13) Rotate the body in the fixture by 180 degrees.
(14) Pick up the choke screw sub-assembly and insert into the valve body.
(15) Pick up the top cover and insert into the valve body.
(16) Automatically feed the piston (19) and insert into fixture (34).
(17) Automatically feed the lip-seal and insert into the piston.
*(18) Pick up O-ring tool.
*(19) Pick up O-ring (16) and insert onto O-ring tool.
*(20) Pick up spool piece (17) and insert into tool.
*(21) Insert O-ring into spool piece.
*(22) Pick up O-ring tool.
*(23) Pick up O-ring and insert into O-ring tool.
*(24) Pick up spool piece and insert into tool.
*(25) Insert O-ring into spool piece.
*(26) Pick up O-ring tool.
*(27) Pick up O-ring and insert into tool.
*(28) Insert O-ring into spool piece.
*(29) Pick up sealing ring (15) and insert onto spool piece.
*(30) Pick up end piece.
*(31) Pick up end piece gasket (21) and insert into end piece.
*(32) Insert end piece sub-assembly into magazine.
(33) Pick up end piece and insert into fixture (35).
(34) Automatically feed and pick up end piece O-ring (20) and insert end piece.
(35) Automatically feed and pick up indicator (24) and insert into end piece.
(36) Automatically feed the piston sleeve (9) and insert into fixture (36).
(37) Automatically feed the O-ring (8) and insert into piston sleeve.
(38) Automatically feed the lip-seal (10) and insert into piston sleeve.
(39) Automatically feed the sleeve (12) and insert into piston sleeve.
(40) Automatically feed O-ring (11) and insert into sleeve.
(41) Pick up piston sleeve and sleeve and insert into fixture (37).
(42) Automatically feed middle sleeve O-ring (13).
(43) Automatically feed middle sleeve (12) and insert into O-ring.
(44) Insert middle sleeve and O-ring into sleeve.
(45) Pick up the body and insert onto sleeves.
*(46) Insert O-ring into valve body.
(47) Pick up sleeve and piston sleeve and insert into valve body.
(48) Pick up piston and insert into piston sleeve.
(49) Pick up end piece and insert into valve body.
(50) Automatically feed end piece screw and insert into valve body.
(51) Fasten end piece screw into valve body.
(52) Rotate the valve body by 180 degrees.
(53) Lubricate the valve.
(54) Insert spool piece tool into body.
(55) Insert spool piece into body.
(56) Remove spool piece tool.
(57) Automatically feed and insert long spring (26) into spool piece.
(58) Automatically feed and insert short spring (27) into spool piece.
(59) Automatically feed and insert pin (28) into spring.
(60) Repeat operations 49 to 51.
(61) Pick up the valve and place onto the test station.
(62) Pick up the gasket (3) and insert into the valve body.
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