Project Background

In the current manufacturing process of inductor coil bending and transferring process at TT Electronics, the inductor coils are manually transferred from the bending station to the soldering station. After bending, coils fall into a container, requiring an operator to transport and manually stack them into a tweezer for the next process. This manual method introduces several inefficiencies:

• Transport: No proper equipment available to transfer the coils to the next workstation.
• Waiting: Manual coil stacking consume time before proceeding to wave soldering process.
• Motion: Unnecessary movement that can cause strain to the posture and the worker becomes easily fatigue.

With a daily production volume of 18,000 units and a manual stacking process that takes 15 seconds for every 20 coils, optimizing this process is crucial to maintaining production efficiency and product quality.

Objectives

• To improve the coil transferring process from bending station to soldering station.
• To design a prototype of coil transferring mechanism.
• To create a self stack coil mechanism while the coil transferring is executed.

By automating these processes, the project seeks to reduce manual workload, enhance workflow efficiency, and improve overall workplace ergonomics.

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Process Time Before Improvement to Identify Bottleneck

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Project Process Time Result Before and After Improvement

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Return of Investments for the Project Process Improvement

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