List of keyences achievements

Kaizen Guide
by Profession
[Automotive and metal industry]
Production Engineering Manufacturing
Maintenance Machine Design/Building
Areas of improvement

01 Production
Engineering 02 Manufacturing

Reduce set-up man-hours Balance work

Reduce startup time of devices Reduce manufacturing man-hours
Improve yield Maintain quality
Improve cycle time Reduce downtime

Traceability Reduce downtime

(2D barcode reader SR-D100)
Reduce startup time of devices
(Safety sensor GL-R)
Reduce set-up man-hours
(Photoelectric sensor LR-Z)
(Photoelectric sensor LV-NEO)
Reduce adjustment time
(Photoelectric sensor GV)
P4.5 Improve yield P6.7
(Flow sensor FD-M)

KEYENCE products will

Solved!
solve customers' problems!

2
The device process for automotive and metal industries
Heat treatment

Washer
Die casting machine Processing machine

Die cast products

Welder

Press machine

Press products

Resin molding machine

Resin moldings

Examples of improvements by
Solved!
equipment are also available!

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 Assembly

Inspection

Assembly and inspection

Parts Press Fitting

Feeder Caulking

O-ring Gear
Installation Installation

Cap Adhesive
Installation Application

Bolt Inspection
Tightening Machine

If you have other problems, please contact us.

Our expertise accumulated through direct sales will help you solve problems.

4
 Read more
about line diagram
by device here.

03 Maintenance
04 Machine Design/
Building

Reduce recovery time Reduce parts costs

Simplify wiring Reduce design man-hours
Standardise components Increase added value of the
Predictive maintenance device
Error proofing

Reduce maintenance man-hours Reduce components costs

(Safety sensor GL-R)
Reduce replacement frequency
(Pressure sensor GP-M)
Reduce recovery time
(Photoelectric sensor PX)
(Photoelectric sensor GV)
Reduce selection man-hours
(Light curtain GL-R)
P8.9 Reduce modification man-hours P10.11
(Image detection sensor IV)

Some themes for improvements are described here.

If you have other problems, please contact us.
Our expertise accumulated through direct marketing will help you solve problems.

5
01 Production Engineering Department

Productivity (2D barcode reader SR-D100)

Poor productivity due to Improving
Problems
errors on 2D barcodes reading. method To improve reading performance
2D barcodes printed directly on metal surfaces could The best reading
not be read stably due to glare and print variation
and therefore the productivity was poor.
settings and filtering
process are selected
automatically to
achieve stable
reading.

Metal Metal Metal (casting

(cylinder) (hairline) surface) Metal (cylinder) Metal (hairline) Metal (casting surface)

Cannot read 2D barcodes. Can read 2D barcodes, that are difficult to capture.

Reduce startup time of device (Safety sensor GL-R)

It takes time to start up Improving
Problems
the device. method Adjusting optical axis instantly
When fitting, the final tightening of the mounting The GL-R won't
brackets may cause the optical axis to deviate.
deviate even when
tightening.

The main body of the light curtain The main body of the light curtain won't rotate even while
rotates when a screw is turned. tightening the fixtures.

Reduce setup man hours (Photoelectric sensor LR-Z)

Reducing sensor Improving
Problems
adjustment time method Eliminating the adjustment of sensor
Because sensor height and sensitivity adjustment LR-Z Datum Mode
is performed each time tooling is changed, it takes
time.
eliminates the need
to adjust of the
sensor.

Adjustment is required. DATUM detection eliminates adjustment.

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 [Example of application]

Points
that make
KEYENCE Best tuning with simplest procedure
Special
Die casting machine

Easy 3 step setting.

SR-D Series
Barcode reading on crankshafts
1 Set,

2 monitor, and Processing machine

3 click SR-D100 Series, Configuration software

AutoID Network Navigator

LV-N Series
Post-process deburring check
Washer

Points
that make
KEYENCE Hardware for adjusting optical axis
Special
Heat treatment

When the conventional hardware is

used, forces act on an object in the GL-R Series
The object
direction of rotation of the main body is inclined, Safety measures for washers
of the light curtain after a screw is causing the
tightened causing the optical axis to optical axis to
deviate.
bend.The GL-R hardware secures right
Press machine
and left nails so that forces act on them
evenly without causing the optical axis
to bend. The optical
axis does not
deviate.
GL-R Series
Safety measures for welders
Welder

Points
that make
KEYENCE What is DATUM detection?
Special
Resin molding machine

DATUM detection is the function

that turns the output on when the LR-Z Series
Center Not return
sensor detects a status other than the Detect presence or absence of gear
registered DATUM. When a workpiece
passes within the detection range of
250 mm, it will always turn the output Reference Workpiece present Workpiece present
Assembly machine
on. This eliminates the need to adjust
the sensor for workpieces of different
(DATUM detection)
heights.
This function detects every state
other than "DATUM". It is effective for
workpieces with asperities or when the
LR-Z Series
light does not return.
Detect presence or absence of
Inspection machine cushioning material

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02 Manufacturing Department

Reduce downtime (Photoelectric sensor LV-NEO)

Because the detection position cannot Improving
Problems
be identified, it takes time to recover. method Identifying detection position
If the optical axis is displaced when using a Adjustment can be
photoelectric sensor, the spot is blurred. This makes
it difficult and time consuming to adjust.
simply performed by
aiming the spot at
the mirror.

It is not easy to determine whether It is easy because the only thing you need to do align the visible point
the optical axis is correct. (spot) with the surface (mirror).

Reduce adjustment time (Photoelectric sensor GV)

Improving
Problems Sensors cannot be adjusted method Installing the device easily at the location to be detected
If the distance between the transmitter and the All you need to do
receiver is long, it may be difficult to install. Drill breaking
is align the visible None

spot with the

location you want to Drill breaking
Present
detect.

The transmitter, the tip of the drill and the receiver The only thing you need to do is aim the visible laser at the tip of the drill.
need to be connected in a straight line.

Stable quality (Contact displacement sensor GT2)

Not noticing the measured Improving
Problems
values being out of alignment method No measured value deviation
Outliers may occur when the response speed is too GT2 adopts a
slow for the equipment vibration. When an outlier World's first

does occur, the deviation will not be noticed and the

unique scale
production will continue. shot system. This
ensures no outliers
occur.

When the spindle moves, the absolute scale also moves.

Complex built-in patterns in the scale are read in high-speed by
the CMOS sensor.
Position information of the spindle is transmitted to an amplifier.
Equipment vibration causes outliers New system without outliers.

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 [Example of application]

Points
that make
KEYENCE Cannon hole transmission
Special
Die casting machine

The LV-S61 Series emits light from

General retro-reflective model
the metal pipe and provides a coaxial GP-M Series
structure around which the receiver is Check processing machine
Transmitter
located This coaxial structure allows clamp pressure
Receiver
constant detection position regardless
Reflector Workpiece
of where a workpiece passes. Processing machine

LV Series retro-reflective model (coaxial)

Reflector Workpiece Receiver PX Series

Detect engine block in a harsh
Washer environment

Points
that make
KEYENCE Washable long range type with 1-meter detection distance
Special
Heat treatment

To withstand a harsh environment in

automotive and metal industries, the GP-M Series
protective structure IP67 is used for the Check press machine pressure
sensor head.The 1-meter long range
type is also available so that the device
can be installed in the area where it
Press machine
can be kept from getting dirty.

FS Series
Detect presence at heat
Welder treatment process

Points
that make
KEYENCE Scale shot system
Special
Resin molding machine

Scale shot system is a system to

identify the absolute position by LV-N Series
reading alternative patterns with the Detect the remaining quantity in a hopper
Absolute value
CMOS sensor. These pattern slits are of the resin molding machine
Transmitter scale
incorporated in the sensor according
to the position. Therefore there are no OK NG
Assembly machine
outliers and the measurement is always
stable.

Shutter speed approx. 6 s.

CMOS sensor
LV-N Series
Detect bolts raised from assembly machine
Inspection machine

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03 Maintenance Department

Reduce maintenance man-hours (Safety sensor GL-R)

Removing equipment and Improved
Problem
cover is a cumbersome task. method Making it simple by eliminating the cover
It is cumbersome to remove the guards and covers Using the GL-R
for maintenance procedures. Only for these parts to
be positioned again and the optical axis re-alligned.
eliminates the need
for making special
covers and jigs!

Removing parts is a cumbersome task. Reduces burdensome task of removal.

Reduce modification man-hours (Photoelectric sensor LV-N)

No Installation space for Improved
Problem
additional sensors. method A sensor suitable to add on to any system
When a sensor is added on to improve a system, Installation position
often the sensor cannot be installed close enough.
of the sensor can
now be determined
before adjusting
spot size.

Sensor could not be installed closer Sensor can be installed before focusing the light on to the part.
and the light un-focused.

Reduce recovery time (Photoelectric sensor PX)

I don't know to what extent the Improved
Problem
optical axis should be adjusted. method Guide for adjusting optical axis
The quantity of light viewed in numerical values can The PX guarantees
be used as a guide when readjusting the optical
axis, however, some people say that they cannot tell
the quantity of
which numerical values would be appropriate. light "9999" with
the optical axis
adjusted!
(For M12 type, up to 4 m of the
detection distance)

Numerical values vary and proper When the optical axis is adjusted, the meter reads 9999.
values are not known.

10
 [Example of application]

Points
that make
KEYENCE Double bumper structure
Special
Die casting machine

This structure stops not only side

Conventional type
impacts but also frontal impacts. The GL-R Series
double bumperstructure completely Prevent entry of a washer
prevents a workpiece of 17 mm or
larger from coming into contact with the
lens, therefore the risk of damage to Processing machine
the vulnerable lens is reduced.
DL-R Series

GL-R Series
Prevent entry into a die casting machine
Washer

Points
that make
KEYENCE Variable spot
Special
Heat treatment

Spot diameter can be adjusted with

a trimmer so that the sensor can be GV Series
added to the system. Also the shape of Handling check
bracket holes are oval so the angle can
be adjusted and the sensor can be fixed
from either right or left.
Press machine

LV-N Series
Trimmer adjustment and locking function Detect remaining part in molds
Welder after press

Points
that make
KEYENCE Installation of a super high brightness LED Vacuum packed structure
Special
Resin molding machine

Combining a red super high brightness

LED with glass lens has enhanced PX Series
the function. Vacuum filling every hole Detect remaining quantity in a hopper
and corner of the case with clear
epoxy resin increases the adhesion
to cables and lens to the utmost limit
Assembly machine
and prevents liquid from entering the
internal circuit. Therefore, it can be
used in a harsh environment.

PX Series
Detect workpieces in a harsh environment
Inspection machine

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04 Machine Design/Building

Reduce components costs (Photoelectric sensor GV)

Costs for making fixtures are Improved
Problem
high. method Reducing the number of components of fixtures
Because there is a drive above a workpiece, The GV Series
mechanical components were necessary to move
the sensor. Extra costs for a cylinder and regulator
can be installed
are needed. diagonally.

When a moving part is included, sensor Since the sensor can be installed in a slanting position to detect, it
needs to be moved by a cylinder to detect. eliminates the need for cylinder.

Reduce selection man-hours (Light curtain GL-R)

Reducing selection errors Improved Selecting the light curtain with a protective area larger
Problem
and selection man-hours method than the overall length of the curtain
When designing a new cell, extra room must be Because the GL-R
added to account for dead zones.
has a structure
without dead space,
the opening can be
securely protected.

The light curtain protrudes from the The light curtain fits into the frontal width.
frontal width.

Reduce installation man-hours (Image detection sensor IV)

Detection part designing for a complex Improved
Problem
shaped workpiece was a trouble. method Stable detection with a single sensor
When there were many detection locations, sensors The IV can do
had to be selected for each location and additional
jigs had to be designed to position the target.
the work of many
sensors. Therefore,
multiple jigs are not
required.

Multiple installations were required. Installation becomes simple.

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 [Example of application]

Points
that make
KEYENCE Automatic 600000-fold control of the quantity of light
Special
Die casting machine

The triangle-range-finding method

based on the CMOS allows detection GV Series
from a slanting position. However the When the workpiece is Detect the level of molten
bright, the sensor
CMOS cannot perform stable detection metal
illuminates weakly
if the reflected light is too strong or too
week. KEYENCE's GV Series offers a Processing machine
600000-fold automatic control of the
quantity of light. This allows users
to perform a stable detection from a When the workpiece is
dark, the sensor
slanting position. illuminates strongly

GV Series
Detect presence or absence
Washer of finished goods

Points
that make
KEYENCE Structure without dead space
Special
Heat treatment

Since the optical axis runs from a

position 5 mm from the end of the light GL-R Series
curtain, and it, has been designed to Safety measures for press
draw a cable from behind the structure machines
is without dead spots.

Press machine

GL-R Series
Detect entry except AGV carrier
Welder

Points
that make
KEYENCE Automatic focus and brightness adjustment
Special
Resin molding machine

The IV Series can adjust focus and

light intensity automatically. Specially Auto-focus
mechanism LV-N Series
developed auto-focus mechanism Detect the length of a shaft
enables one-touch high-speed focusing
and light intensity adjustment.

Assembly machine

IBA processor

HP Quad lens CZ Series

Hi-R illumination
Differentiate connector colors
Inspection machine

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 list of keyences achievement

Kaizen Guide
by Profession
[Automotive and metal industry]

www.keyence.co.uk
E-mail: ukinfo@keyence.co.uk

Copyright (c) 2013 KEYENCE CORPORATION. All rights reserved. KaizenAutoDepartment-WW-AG-GB 1073-1 600B82