Setup Reduction Module. The benefits of quick changeover 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
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The biggest opportunity for improvement is in reducing the look time for gathering items and eliminating the need to make adjustments.
Work that must be done while the machine is stopped
Work that can be done while the machine is running
List of all tools, gages, fixtures, etc. necessary to complete the setup
Plates, spacers, or frames that eliminate the need to make major changes during the setup
Single minute exchange of dies-----the goal of all setup reduction projects
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.
Move material into work area E
Loosen 6 cap screws I
Remove chuck jaws I
Remove work stops I
Change inserts I
Get part prints E
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 pre-adjusted while the old parts are running.
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
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.