2400 pcs/day Alignment Simulator

Recommended planning values are pre-loaded. Adjust them during customer discussion and replace with actual values after site study / time study.

Options 1-3Two-robot S5–S6AMR/MR fleet8 hr run + 1 hr chargeFull process map

Customer Input Register

Orange fields are values to be provided or confirmed by Collins before the simulator result is used for final proposal costing.

S1 Grindingmachine count, cycle time, load/unload method, tray orientation

S1 Inspectiongauge list, inspection time, pass/fail, rework/scrap route

Transfer Routedistance, route speed, traffic delay, manual vs AMR/MR selection

S2 Superfinishmachine count, process time, tray exchange, output orientation

S3 Degreasebatch capacity, degrease time, blow-off, drying/cooling time

S4 Conveyorlength, speed, buffer capacity, tray presentation time

S5-S6 Existingrobot loop, datum/dummy, OD sizing, laser, vision, GO/NG unload

Controls/DataPLC map, tags, OPC-UA/MES/SAP, recipe and traceability fields

Selectable modules: manual transfer, AMR/MR, cobot/robot loading, second S5-S6 robot, indexing/buffer. Only selected modules should be included in the final option calculation.

1. Full Process Link Flow

The visual flow is used by the calculation engine. Disabled stages are greyed out when a lower option is selected.

2. Proposal Scenario

Scenario preset S5-S6 architecture

Include S1 Grinding / AMR link Include S2 Superfinish Include S3 Degrease Include S4 Conveyor / buffer Include AMR/MR transport capacity

3. Production Basis

Target good output / day Shifts / day Hours / shift OEE % First-pass yield % Batch size / tray Planned transfer loss (min/day) Design headroom %

-Hard takt limit

-Recommended design takt

-Calculated bottleneck

-Estimated good output/day

-Target status

4. Recommended Result

5. S1-S4 Stage Timing Inputs

All values are proposal placeholders. Replace with actual timing after site time study.

S1 Centerless Grinding + Cobot + Inspection

Cobot service time (sec/pc) Grinding process (sec/pc) Inspection lane (sec/pc) Index + reject allowance (sec/pc)

S2 Superfinish / Polishing

Handling service (sec/pc) Superfinish process (sec/pc) Index allowance (sec/pc)

S3 Degreasing + Blow-Off + Cooling

Degrease (sec/tray) Blow-off / drying (sec/tray) Cooling allowance (sec/tray) Load/unload handling (sec/tray)

S4 Conveyor / Buffer

Conveyor distance (m) Conveyor speed (m/s) Index + buffer allowance (sec/pc)

6. S5-S6 Robot Cell Inputs

Reference one-robot baseline

One-robot service loop takt (sec/pc)

Robot A - Sizing Lane

Pick / orient (sec) Datum / dummy measurement (sec) OD sizing (sec) Buffer place / handshake (sec)

Robot B - Marking / Output Lane

Pick from buffer (sec) Laser nest load (sec) Laser marking (sec) Vision verification (sec) GO/NG unload (sec) Exchange allowance (sec) Robot cell margin %

7. AMR / MR Route, Charging & Fleet Sizing

Use this to evaluate one AMR/MR versus two AMR/MR units. Default is two units for charging coverage and redundancy.

Route Timing

Selected fleet size Loaded distance total (m) Empty return distance (m) Loaded speed setting (m/s) Empty speed setting (m/s) Site speed limit (m/s) Route efficiency %

Docking / Wait / Demand

Pickup dock time (sec) Inspection/drop dock time (sec) S2 drop dock time (sec) Handshake allowance (sec) Traffic / queue wait (sec) Route legs per batch Extra rework routing % Trays per AMR/MR trip

Battery / Availability

Run time per charge (hr) Charge time (hr) AMR/MR availability % Recommend N+1 / charging coverage

AMR/MR 1

AMR/MR 2

-Trip time

-Required trips/hr

-Capacity / AMR

-Calculated minimum

-Recommended fleet

-Selected fleet utilization

8. Detailed Stage Result Table

Stage / link	Included	Calculated takt	Formula basis