Setup Reduction

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Setup Reduction
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Justify the Need for a Project

• Never storm into a setup reduction project
  without first reviewing the suppliers operation.
  Will the project
• Benefit Oshkosh, Pierce, McNeilus?
• Benefit the Supplier?
• Reduce WIP levels?
• Reduce Manufacturing Critical-path Times?
• Add capacity to achieve production?
• Reduce the suppliers PPM rates?
• Increase manufacturing flexibility?
• Lower overall operating costs?

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Waste Attributed to Setups

• Overproduction.
• Excess inventory.
• Defects.
• Non-value added processing.
• Waiting.
• Transportation.
• Under-utilized people.
• Excess motion.

4
Setup Reduction Benefits

• Shorter lead time.
• Less material waste.
• Fewer defects.
• Less inventory.
• Lower space requirements.
• Higher productivity.
• Greater flexibility.

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Setup Reduction Reduces Waste

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Select the Appropriate Machine

• Select a single machine for the initial setup
  reduction project.
• Techniques to select the initial machine
• MPX flow modeling.
• Process mapping.
• Spaghetti diagrams.
• Set-up metrics.
• Excessive queues.
• Excessive WIP.
• Excessive finished goods.
• Factory tour.

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Roles and Responsibilities

• Draft a project charter that includes the
• Business Case.
• Situation and Goal Statement.
• The mission and vision.
• Project Scope.
• Schedule and deliverables.
• Assignments and roles.
• Responsibility of the Champion.

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Change Agent and Motivator

• Gear the Charter to
• Commit resources from the company.
• Reduce setup times by at least 50 on the first
  attempt.
• Keep the budget as low as possible.
• Obtain input from all shifts.
• Set new standards for metrics and documentation.
• Generate quick results.

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Reasons Why Projects Fail

• Watch out for the following
• No commitment of funding or manpower.
• No plan of action to direct work effort.
• Project Manager not given adequate time.
• Project not implemented correctly.
• People affected by change not included.

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Spread the Word

• Schedule rollout meetings ASAP to kill the rumor
  mill.
• Communication is a critical component for
  success.
• Company leadership must be present.
• Try to invite all that touch the process.
• Explain why the setup reduction project is
  needed.
• Introduce the concept of teamwork, metrics, and
  value add.
• Good people working in a less than desirable
  process.
• Assure employees that videos will not be used
  against them.
• We are not here to purchase your business.

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Explore the Real World

• Identify every day Need for Speed applications.
• Fast Food Subway, Quiznos, etc.
• Ten minute oil change Pennzoil
• Pit stops NASCAR, CART, etc.
• Grocery stores Express checkout
• Banks ATM machines, On-line banking
• Shopping Internet

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Historical Data to Viable Metrics

• We cant fix what we cant measure.
• Request 12 month history for all available data
• Setup rates.
• Machine uptime.
• Planned and unplanned machine maintenance.
• Actual pieces produced, lot sizes, and runs per
  year.
• Scrap rates.
• Required tooling.
• Delivery performance.

Map and Measure
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Setup Reduction Team Members

• Setup Reduction Teams need to be cross-functional
  and include people who touch the process
• Maximum of five full time members.
• Operators and setup personnel.
• Supervisors and schedulers.
• Maintenance and tool makers.
• Engineers and Quality Control.
• Information Technology.
• Encourage the use of part time resource people.
• Representation on all shifts.

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Definition of Setup Time

• Start the clock
• When the last completed part of Job A is
  produced.
• Stop the clock
• When you are confident that Job B will
  produce quality parts at normal production rates.

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Typical Setup Process

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Internal Setup Elements

• All activities that must be performed while the
  machine is held captive and not making parts.
• Removing installing clamps.
• Removing installing hoses.
• Removing installing safety guards.
• Removing installing tooling.
• Moving major machine tool components.
• Cleaning machine surfaces.

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External Setup Elements

• Any activity that can be performed while the
  machine is making parts.
• Tool cleaning and maintenance.
• Preparing paperwork and job instructions.
• Staging tooling and raw material.
• Verify part number run priority.
• Staging part and scrap removal containers.

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Video is a Must

• Video taping the setup is critical to identify
  all the steps and their associated times.
• Video taping can be a major obstacle in the
  plant.
• Be sure to have date and time stamps on the film.
• Video tape anything and everything.
• Be sure to capture the entire area crows nest
  approach.
• Do not take short cuts, even if the taping
  process is painfully time slow.
• Film multiple setups on multiple shifts if
  required.
• Be sure to capture the correct camera angle.
• Follow the definition of setup time religiously
  when taping.

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Benefits of Using Video

• Enables instant replay.
• Allows the operator time to explain the process.
• Makes it easier to study the elements.
• Increases objectivity.
• Stimulates the exchange of ideas.
• Increases involvement.

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Verify Collected Data

• Collect fresh production data if time allows.
• Scrub pre-team production data for accuracy.
• Review the video tape and note
• The activity and time required.
• Names of all employees in the process and their
  shifts.
• Classify the activity as either internal or
  external.
• Identify all hand tools and who owns these tools.
• Identify all hardware components in detail
  size, pitch, etc.
• Note any obvious process improvements.
• Publish existing job change metrics.

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Remember the Facts of Life

• KISS
• Keep it simple Sam.
• 6 Ps
• Proper Planning Prevents Pitiful Poor
  Performance.
• CKM
• Closest Knows the Mostest.

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Keys to Success

• Planning
• Organization
• Teamwork
• Standardization
• Out of Machine Setup Time
• Ownership
• Mindset
• Staying Power

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Brainstorming New Ideas

• Review current documentation and video tapes for
  areas of improvement.
• Review every job change element trivial to
  significant.
• Review best practices films, photos, books, etc.
• Listen to all ideas.
• Adhere to the team charter for project scope.
• Use a parking lot approach to document out of
  scope ideas.
• Disqualify ideas that compromise safety or
  quality.

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Try to Eliminate Activities

• Typical activities to address
• Go Fetch Find and travel distances.
• Machine adjustments.
• Non-standard hardware, settings, etc.
• Manual positioning and clamping.
• Secondary operations.
• Excessive maintenance.
• Work instructions and duplication of paperwork.
• Second party inspection and part qualification.
• Job assignments and staffing.

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Work Area Diagrams

•  

 
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All Forklift Trucks are Evil

• This versatile piece of equipment
• Is never available when you need it.
• Can easily be used in an unsafe manner.
• Can damage everything within reach.
• Requires certification to operate.
• Promotes an internal job change mindset.

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Dont Rush Implementation

• Select a single machine for implementation.
• Perform multiple changeovers.
• Perform a safety risk assessment.
• Learn what works and what does not.
• Suggest enhancements and test them.
• Professionally document all required work
  instructions, job descriptions, and metrics.

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Housekeeping Enables Success

• You can tell a lot about the management of a
  factory by its housekeeping practices.
• Safety Quality Delivery metrics.
• Employee attitude turnover.
• Be sure to
• Clean the work area at the end of each shift.
• Clean and inspect all tooling after the run.
• Shadow board approach for tool storage.

Control
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Coordinate External Work

• Advanced Planning is critical
• Create setup checklists.
• Coordinate maintenance activities in advance.
• Color code fixtures and tools.
• Locate tool storage as close as possible.
• Start setup preparation before the last part is
  run.
• Plan for extra manpower as needed.
• Document any new revisions ASAP.

Control
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When We Have a Success

• Paint the ceiling white.
• Give the machine a fresh coat of paint.
• Make the work area stand out from the rest.
• Have a factory celebration pizza, brats, etc.
• Document the project SD that Works, etc.
• Update fellow employees.
• Team Recognition plaque, etc.

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Take a Team Photo