Transcript Setup Reduction Module

Setup Reduction Module
• The benefits of quick changeover
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Meet customer needs
CIPP Buyouts (more time for output)
Smaller lot sizes
Reduced inventory
Reduced cost
On time delivery
Production smoothing
Waste elimination
Higher quality
Increase cash flow
Flexibility in scheduling
Reduce lead time
Increase profitability
Definition of Setup Time
• The amount of time taken to change
a machine from the last part of a
production lot to the first good part
of the next production lot.
• Including gauging and fine tuning
• Clock time, not labor time.
Typical Setup Process
• Gathering necessary items
25%
• Exchanging parts
10%
• Positioning parts
20%
• Making adjustments
45%
The biggest opportunity for
improvement is in reducing the look
time for gathering items and
eliminating the need to make
adjustments.
Setup Reduction Terminology
• Internal Setup
Work that must be done while the
machine is stopped
• External Setup
Work that can be done while the machine
is running
• Equipment List
List of all tools, gages, fixtures, etc.
necessary to complete the setup
• Intermediate Jigs
Plates, spacers, or frames that eliminate
the need to make major changes during
the setup
• SMED
Single minute exchange of dies-----the
goal of all setup reduction projects
Setup Reduction
• Step 1
Separate the work that must be done while
the machine is stopped (internal setup)
from the work that can be done while
the machine is running (external setup).
Create a list of all setup activities and
label whether they are internal or
external.
Example:
Move material into work area
Loosen 6 cap screws
Remove chuck jaws
Remove work stops
Change inserts
Get part prints
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Setup Reduction
• Step 2
Reduce internal setup by doing more
work externally. Determine the
baseline time necessary to complete
each setup element. Next determine the
true function and purpose of each
internal setup element and brainstorm
ways to do them externally or
eliminate.
Prepare dies, fixtures, and gages outside
the machine environment while the old
parts are still being machined.
Necessary tools should be gathered and
laid out in proper sequence of use while
the machine is still running old parts.
Use setup carts when appropriate.
Minimize the number of adjustments by
standardizing, using dowel pins, and
precision locators etc. Duplicate
tooling and equipment can be preadjusted while the old parts are running.
Setup Reduction
• Step 3
Streamline all internal and external
elements that have been recognized as
still necessary.
Make sure that the setup elements are being
done in the most advantageous order and
means possible. Simplify or eliminate
the need for adjustments and tweaking by
developing gadgets, set blocks. Use
quick change tooling such as chuck jaws,
commonize nuts, bolts, and hardware.
Use a setup team approach if necessary to
reduce the time the machine must be
down during the setup.
Involve many disciplines such as
toolmakers, processors, operators,
quality, and IE’s
Setup Reduction
• Step 4
Fine tune all elements of the setup by
training the operators and timing the
new setup process. Again look for
ways to reduce the time of the longest
elements.
Retime and observe until the operator has
the new process nailed.
“Operating Room” analogy
Once the new setup procedure is
defined create a SOP (Standard
Operating Procedure) that is
laminated and posted at the machine
for use by all operators.
Key Activities
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Set an improvement target
Observe the setup as is
Brainstorm improvements
Create action item list
Prioritize implementation
Assign Tasks to team members
Develop new procedure
Perform & time new procedure
Train all operators
Repeat the setup---practice and
retime until all operators are efficient
at the new procedure
• Create SOP, laminate and post
Setup Reduction Techniques
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Use color coded equipment
Commonize components
Commonize wrenches
Use air or cordless tools
Use hydraulic or air clamping
Use digital pictures to document SOP
Use precision locators
Die carts
Shadow boards
Organize and label all equipment
Use a video camera
Use PERT to define the critical path
Eliminate the setup altogether by
using dedicated machines if possible