SETUP IMPROVEMENT Setup Definition The setup includes everything

SETUP IMPROVEMENT

Setup: Definition • The setup includes everything, all elements and time from the last good piece of the previous job until the first good piece of the next job. • In essence, Setup considers the ACTIVITES and TIME SPAN from GOOD PIECE (A) to GOOD Piece (B)

What setup reduction is not • Not to reduce set-up people – A 50% reduction in setup time will not lead to a 50% reduction in setup people. Typically no reduction in setup people. • Not to produce more product – (except when capacity is a issue)

WHY Reduce Setup times? • Key reason is to Reduce Lot Sizes • Reduced WIP • Reduce Lead Time • Better Quality • Flexibility

Work Content Breakdown Ex. • Preparation, after-process returns, and checking of raw material, blades, dies, jigs, gauges, etc. • Mounting and removing blades, fixtures, chucks, etc. • Centering, dimensioning, & setting of other conditions • Trial run & Adjustments • 30% • 5% • 15% • 50%

Two Kinds of Setup Activity • Internal – Can be performed only when the machine is shut down, or process is not producing. • External – Can be performed while the machine is running, or process is producing.

Fundamental Rule • If an ACTIVITY can be done with the process is running (externally), then it should be done while process is running.

Where to Start • • Bottlenecks Short Lead-time Customer Complaints Delivery

Guidelines & Tips • Review and Document current layout & process – Data Collection • The complexity of the job change will determine how many observations needed • View complete change over whenever possible • Simulate change over when feasible • Video Record • Process Map • Fishbone

Guidelines & Tips • Evaluate process, look for possible enhancements. Incorporate the operator, supervisor, processor, setup person, etc. in the evaluation. • Separate internal and external activities • Reduce internal activities by doing more work externally • Brainstorm for improvements

Guidelines & Tips • Reduce/improve both internal and external activities – Internal • • • Standardize Fixtures Locating Pins Standardize die heights Predetermined X-Y coordinates in CNC machines Standardize & improve clamping methods Reduce the number of bolts

Guidelines & Tips • • • Standardize bolt heads Cut off unnecessary threads U-Washers SPC - Pre-control charts T-slot and U-slots in base plates – External • Eliminate adjustments - potential 40% to 50% • Maintenance of tools, gages & fixtures

Guidelines & Tips • Preset tools and position dies • Assign additional people to setup when feasible • Pre-stage all items - Die carts, tool boards – get tooling, fixtures, dies, and molds • • Dismantle and repair items Clean up Return tooling What paperwork/necessary computer information • Reduce internal activities by doing more work externally

Guidelines & Tips • Coordinate and plan external work – Create a Setup Chart – Color code fixtures and tool – Code location and description of dies – Locate storage as close as possible – Start preparation before the last part is run – Plan for extra manpower

Guidelines & Tips • KEEP AN OPEN MIND, ASK “ WHAT IF” • Test ideas and measure results • Implement improvements • Document the new process

In Conclusion • Quick reaction to the DEMANDS of the market is critical. The ability to give your customers WHAT, WHEN & HOW MUCH they want is essential. Efficiently changing from one job to another job is a MUST.