Transcription
Stéphane Chateau, October 2010ABB Robotics Service RRCParts Repair & Robot Reconditioning
Parts & LogisticsBackend unitsSEDELogistic CenterPart SupportJPMXPart NPart Support41 Frontend units ABB GroupMarch 20, 2013 Slide 2
Common Service Support from backend unitsCommon OfferingNew PartsExchangePartsRepair PartsReconditionedProductsSupply Management (Sourcing), Quality Management (certifications),Life Cycle Management, Price ManagementCommon Management System ABBFebruary 4, 2010 Slide 3
Parts and LogisticsCertified Part Repair and Robot ReconditioningCZStandardized repair procedures,e.g. wrist IRB 1400MX
Focusing countries of OstravaOstrava ABB Group , Certified Repair CenterMarch 20, 2013 Slide 5
Ostrava today ABB GroupMarch 20, 2013 Slide 6
Focusing countries of San Luis PotosiSan Luis Potosi ABB Group , Certified Repair CenterMarch 20, 2013 Slide 7
Certified Center, Parts Repair & Robot ReconditioningGuidelines Part repairs and Reconditioning of robots need a highlevel of competence, tools, test bench and are onlyhandled by the Certified Repair Centers. Only ABB original parts are used in the repairprocess and the reconditioning process Our targeted models are S4C, S4C , IRC 5, The spare parts repair delivery time to customers is2-3 weeks. ABB GroupMarch 20, 2013 Slide 8
Products definition Robots reconditioning : 3 products Reconditioned robots (Premium, Standard, Basic)RefurbishmentABB stockCustomer AABB stock refurb robotsCustomer B Customer property refurbishment (after 6-7 years)RefurbishmentCustomer A Mechanical arm exchangeABB stockCustomer BCustomer A ABB GroupMarch 20, 2013 Slide 9RefurbishmentOld mechanical unit (ABB property)
Process1st startingStockStartingFinal testsAuditTemporary repairPre Tests,calibrationManipulatorauditRunningMini 16hCabinetauditCabinetPaintFinal grefurbishmentRepairManipulatortests ABB GroupMarch 20, 2013 Slide irCabinet testsCustomer configurationStock
Audit Objectives To evaluate thecondition of the robot : Decision ifrefurbishment ispossible (YES/NO) Define a detailedrefurbishment plan Premium Refurb. Standrad Refurb. Basic Refurb. ABB GroupMarch 20, 2013 Slide 11 Audit Visual inspection Dynamic behavior Play measurement Brake control Motors control Report
Audit152 checking points ABB GroupMarch 20, 2013 Slide 12
AuditVisual inspection Objectives Check Gearboxes leakage Shocks Cracks foundries Cleanliness . ABB GroupMarch 20, 2013 Slide 13
AuditDynamic behavior Objectives To detect Noise, slapping Irregular movements Instability on point :vibrations Remarks The slapping, the noise arewarning play, wearpinion/bearing, pollution of oil ABB GroupMarch 20, 2013 Slide 14
AuditPlay measurement Objectives To measure the play foreach axis Measurements takenwith dial indicators andwith establishedpositions Measurement withoutload (axis 2 and 3 :equilibrium position) Remarks References : criteriaidentical to a new robot ABB GroupMarch 20, 2013 Slide 15
AuditOil analysis Objectives To determine oil/greasepollution Metal particles Remarks The oil analysis is anHELP Allows to determine if acomponent is indestruction phase(bearing, pinion, ) ABB GroupMarch 20, 2013 Slide 16
AuditBrakes control Objectives To control slippage Remarks Test with nominal load Robot in running ABB GroupMarch 20, 2013 Slide 17
AuditMotors control Objectives To control insulations Detection degradationof the insolents shortcut Remarks Controls are taken on thebase of the manipulator In the event of wrongvalues, the cablemanipulator and themotor are controlledindependently ABB GroupMarch 20, 2013 Slide 18
Refurbishment Manipulator refurbishment: Oil and grease replacement Lubrication bearing axis 1 Manipulator dismounting Cleaning Manipulator mounting Standard and systematicreplacement of some parts SMB Board batteryreplacement Internal cables ABB GroupMarch 20, 2013 Slide 19
Refurbishment Manipulator Refurbishment Bearings replacement Parallel arm Articulations ofbalancing units Articulation betweenaxis 2 and 3 Guiding ring rods onbalancing unitsreplacement (IRB6400) ABB GroupMarch 20, 2013 Slide 20
Refurbishment Manipulator refurbishment: Standard and systematicreplacement of someparts Process “Press standing”,Foundry : bearing axis 1 Replacement of otherparts according to Auditreport Tests ABB GroupMarch 20, 2013 Slide 21
RefurbishmentWrist unit Manipulator Refurbishment Wrist Replacement of theintermediate wheelbearing axis 5 Adjustment of playaxis 5 Replacement of thebearing, sealingarticulation motoraxis 6 Motor axis 6replacement ABB GroupMarch 20, 2013 Slide 22
RefurbishmentController Cabinet refurbishment: Cabinet dismounting Trafo, cables, Complete interior andexterior cleaning Components cleaning Drive unit Power unit Board Computer I/O ABB GroupMarch 20, 2013 Slide 23
RefurbishmentController Cabinet refurbishment: Standard andsystematicreplacement of someparts Fans Filter Contactors Batteries Floppy disc Gasket ABB GroupMarch 20, 2013 Slide 24
RefurbishmentTeach pendant Teach pendant Standard andsystematicreplacement of someparts Keyboardreplacement Top housingreplacement ABB GroupMarch 20, 2013 Slide 25
RefurbishmentParts replacedOil and grease replacementCleaning ABB GroupMarch 20, 2013 Slide 26
Tests1 hourRunning test afterrefurbishmentCalibration & TCP testAccuracy test beforefinal running test16/24 hoursRunning testAccuracy test afterfinal running test ABB GroupMarch 20, 2013 Slide 27
RefurbishmentSafety stickers Paint & Safety labels ABB GroupMarch 20, 2013 Slide 28
What you receivedAs good as new one ABB GroupMarch 20, 2013 Slide 29
Differences from ABB with traders Fully refurbished robot (Premium or Standard) Customized robot (example CP/CS, I/O board, Cableslength ) Robots are delivered with CE-IIB document. This isrequired to be able to create the CE-IIA document. We will be in line with the new machine Directive 13849during 2010 Robots are delivered with all documentation on CD. Robots are delivered with key-disk. Warranty: Full warranty on parts and hours. ABB GroupMarch 20, 2013 Slide 30
Quality ABB GroupMarch 20, 2013 Slide 31
Price ManagementCategorizing parts on customer value and competitionGlobalSalesPrice100New 40New CostGMPartRepair Cost ABB Group , Certified Repair CenterMarch 20, 2013 Slide 32Delivery time
Repair ProcessPart arrival in OstravaDay 2/3NAudit at receptionYPrepare repair estimateNLDU accept the estimateYCannot be repairedor estimate rejectedby LDU :- Scrapped- Sent back- Audit invoiced ABB Group , Certified Repair CenterMarch 20, 2013 Slide 33 ? Day4/13Repair processReturn shipmentDay 14
Repair3 products Repairable parts ABB GroupMarch 20, 2013 Slide 34 Wrists Motors FlexPendant/TeachPendant
RepairWhat we need for a repair Traceability Components Genuine parts Knowledge/skill Training/support from manufacturer Drawings/ technical data Tools Tests before and after repair Test bench (validated by manufacturer) ABB GroupMarch 20, 2013 Slide 35
RepairTraceability All the parts are identified atthe arrival LBU Part article number Serial number All the documents arestored in a data base All the steps for the repair Technician name Date ABB GroupMarch 20, 2013 Slide 36
RepairProcesses Standard process for each task ABB GroupMarch 20, 2013 Slide 37
RepairComponents We buy allcomponents directlyto the manufacturer orsupplier (followingmanufacturerspecifications) ABB GroupMarch 20, 2013 Slide 38
RepairTechnical data Drawings and technicaldata from manufacturer Working instructions ABB GroupMarch 20, 2013 Slide 39
RepairTools To assemble anddisassemble the parts Specific tools, . ABB GroupMarch 20, 2013 Slide 40
RepairTest bench Allows a fast andreliable diagnosis Certify the repair ABB GroupMarch 20, 2013 Slide 41
Our repair workshopWrist line ABB Group , Certified Repair CenterMarch 20, 2013 Slide 42
Arguments for Certified Repair & Reconditioning Centralized competence Controlled processes Quality Investments in Assets / Tools / Test benches Access to original data (drawing, BOM ) with supportfrom original manufacturer Direct contact with original suppliers for repair Use only original components Buy back power Central inventory available Repaired parts available in the reconditioning of robots ABB GroupMarch 20, 2013 Slide 43
ABB GroupMarch 20, 2013 Slide 44
March 20, 2013 Slide 9 Products definition Robots reconditioning : 3 products Reconditioned robots (Premium, Standard, Basic) Customer property refurbishment (after 6-7 years) Refurbishment Mechanical arm exchange ABB stock Customer A ABB stock Refurbishment ABB stock refurb robots Customer B Customer A RefurbishmentCustomer A
