Steps for Setup Time Reduction in Manufacturing Processes

For many manufacturing procedures, setting up a mechanism to change from one product to the next is the main part of the procedure. Because it is a hassle, try to do it as uncommonly as possible, so don’t get good at it and it takes a long time and need to run large batches to justify long setup times. Applying a Lean Enterprise turns this theory on its head – to decrease inventory and make smaller batches, so need to set up more often and essential to decrease the time it takes so costs don’t blow-out. Kanban Management Training PPT will help to learn to set-up point-of-use material storage, interface pull systems with current planning systems and set lot sizes based on capacity, not economic order quantity theory. The advantage is, doing setups more often means get better at it. Here are the steps to take when addressing setup time reduction.

Observation: Firstly, let’s perceive the setup procedure; note the steps and how long each step takes. Note how far the worker has to travel to get the tools, dies and material that needs. All of these observations will help in understanding the challenges in each setup.

Eliminate Obvious Waste: This is where good housekeeping and Practical 5S is so significant. Every minute the machine is changing over is idle is lost time, so don’t want the operator to spend any time looking for things or information – it all requirements to be at hand and good 5S will assist here.

Classify Internal and External Setup Steps: Now that the apparent waste is removed, essential to look at each step and determine if it is internal or external setup. Internal setup is the steps that must be done when the press is stopped. External setup is the steps that can be done while the machine is still running.

Need to think about machine setups this way to – look at each step and ask if this can be done while the machine is still running. Tasks like significant which die to load next, finding the material and work orders, having all of the hand tools at hand. These can be done earlier the last run stops. It may be the worker that does these tasks; it may be a setup person or supervisor. Business will essential to control the best way to do this for situation. Having all tools obviously recognized and stored in a set location will make finding the tools easier.

Decreasing Internal Setup: As soon as the last run is ended the changeover starts and racing against the clock to get the machine running again – everything desires to be ready. To help color code bolts and paint the front of the dies to make it clear which way they go into the press. Making simple, one-page setup cards will also decrease the internal setup times. These cards show the significant information and dimensions, clearly layered out. The worker can easily remind himself of the details of this particular setup.

Monitor and Enhance: After the original setup decrease blitz, begin to measure and record each setup. Have the charts exhibited by each machine with targets and space to note enhancement ideas and where things may have gone wrong for a particular setup. Meet each week to deliberate setups and enhancement ideas.

Source:

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