Setup Time Reduction Using Single Minute Exchange of

12/1/2020 Copyright-Lean Quality Associates, all rights reserved 2

www. leanquality. net n n n n n In the beginning, there was…STORAGE. Definitions

Lean Definition: “A systematic approach to identifying and eliminating waste(non-value-added activities) through continuous improvement

About Lead Time n “One of the most noteworthy accomplishments in keeping the price

Set Up Time Definition: “The time between the last good piece off the current

Historical setup Procedures 30% 50% n Preparation n n n 15% cleaning up completed

Wastes in Set-Up n Defects n Overproduction n Waiting n Non-utilized people n Transportation

Traditional setup Assumptions n n Long runs are necessary to amortize the cost of

Traditional setup Math Do these assumptions make sense if setup time can be significantly

Economic Order Quantity (EOQ) 12/1/2020 Copyright-Lean Quality Associates, all rights reserved 11

Effect of SUTR on EOQ 12/1/2020 Copyright-Lean Quality Associates, all rights reserved 12

The SMED System n S ingle M inute E xchange of D ie n

Reducing setup Time n Put the “basics” in place n n workplace organization 5

SMED: Basics n There are two types of setup tasks: n n n internal

The Stages of SMED • • • 1 -Separate internal and external steps 2

12/1/2020 Copyright-Lean Quality Associates, all rights reserved 17

Streamline all elements. n n n n Parallel operations Eliminating adj. Functional clamps Mechanization

Experience with SUTR n n Cold Rolling Mill 62 min to 16 min Grinding

Additional questions? n n n n Industrial Engr. Lean & Lean Six Sigma RABQSA-Principal

Slides: 20

Download presentation

www. leanquality. net n n n n n In the beginning, there was…STORAGE. Definitions of TIME Typical Old procedures /Wastes EOQ Assumptions / Computation Improvement process / SMED Necessary cultural preparation Basics & Principles Typical Results Q&A 12/1/2020 Copyright-Lean Quality Associates, all rights reserved 3

Lean Definition: “A systematic approach to identifying and eliminating waste(non-value-added activities) through continuous improvement by flowing the product at the pull of the customer in pursuit of perfection” 12/1/2020 Copyright-Lean Quality Associates, all rights reserved 4

About Lead Time n “One of the most noteworthy accomplishments in keeping the price of Ford products low is the gradual shortening of the production cycle. The longer an article is in the process of manufacture and the more it is moved about, the greater is its ultimate cost. ” Henry Ford, 1926 12/1/2020 Copyright-Lean Quality Associates, all rights reserved 5

Historical setup Procedures 30% 50% n Preparation n n n 15% cleaning up completed job receiving instructions for next job storing/retrieving tools, parts, materials checking functionality Parts removal and attachment Centering, dimensioning, and setting n n 5% tools, dies, jigs, gauges Trial processing and adjustments 12/1/2020 Copyright-Lean Quality Associates, all rights reserved 7

Wastes in Set-Up n Defects n Overproduction n Waiting n Non-utilized people n Transportation n Inventory n Motion excess n Extra processing Typically 95% of Total Lead Time is Non-Value Added!!! 12/1/2020 Copyright-Lean Quality Associates, all rights reserved 8

Traditional setup Assumptions n n Long runs are necessary to amortize the cost of setups Managing production using economic order quantities (EOQ) balances setup costs and inventory carrying costs 12/1/2020 Copyright-Lean Quality Associates, all rights reserved Inventory 9

Traditional setup Math Do these assumptions make sense if setup time can be significantly reduced? setup Cost + Inventory Carrying Cost Variable Cost setup Cost Fixed Cost 12/1/2020 EOQ Copyright-Lean Quality Associates, all rights reserved Lot/Batch Size 10

The SMED System n S ingle M inute E xchange of D ie n n n Step-by-step method to reduce setup time Developed by Shigeo Shingo Applicable in all industries Useful in streamlining other processes setup in under 10 minutes 12/1/2020 Copyright-Lean Quality Associates, all rights reserved 13

Reducing setup Time n Put the “basics” in place n n workplace organization 5 S’s visual controls Analyze and improve setup using SMED 12/1/2020 Copyright-Lean Quality Associates, all rights reserved 14

SMED: Basics n There are two types of setup tasks: n n n internal (machine down) external (machine running) Eliminating or streamlining a setup task requires a clear understanding of that task’s real purpose and function Focus first on no/low cost solutions The best setup is no setup! 12/1/2020 Copyright-Lean Quality Associates, all rights reserved 15

The Stages of SMED • • • 1 -Separate internal and external steps 2 -Convert internal to external 2 -Streamline all aspects of setup operations. 1 12/1/2020 Copyright-Lean Quality Associates, all rights reserved 16

Streamline all elements. n n n n Parallel operations Eliminating adj. Functional clamps Mechanization Planning Work place Layout Team/Organize Training 12/1/2020 n n Pit-Crew Practice Documentation Copyright-Lean Quality Associates, all rights reserved 2 18

Experience with SUTR n n Cold Rolling Mill 62 min to 16 min Grinding Op 35 min to 10 min Press Brake 16: 51 min to 7: 08 m Vacuum Evaporator 65 min to 22 min 12/1/2020 Copyright-Lean Quality Associates, all rights reserved 19

Additional questions? n n n n Industrial Engr. Lean & Lean Six Sigma RABQSA-Principal Auditor ISO-9000, TS-16949, 17025 (262)-834 -8476 jerryvpmep@comcast. net www. leanquality. net 12/1/2020 Copyright-Lean Quality Associates, all rights reserved 20