Setup Reduction Workshop

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Setup Reduction Workshop

• June, 2009
• Rick Bohan

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Agile Manufacturing Ideal

• Make exactly what customers want,
• exactly when they want it
• In exactly the right quantities
• Without waste

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Why Reduce Setups?
Competitive Advantage
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The Benefits of Quick Change

• Flexibility
• Quicker Delivery
• Better Quality
• Lot-size can be reduced.
• Help to reduce inventory.
• Increase capacity on bottleneck equipment.
• Help to eliminate setup scrap.

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The Benefits To Workers

• Safer Setups and Changeovers
• Less Frustration
• Less Workplace Clutter
• More Consistency

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The amount of time taken to change a machine from
the last good part of a production lot to the
first good part of the next production lot.Clock
time! Not labor time!
Setup Reduction
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Typical Setup Process

• Preparation, checking materials 30
• Exchanging tooling 5
• Measurements and settings 15
• Trial runs and adjustments 50

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Two Kinds of Setup Steps

• Internal Must be done with machinery off.
• External Can be done while machinery is running.

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Setup Time Reduction
External Setup Steps
Present Setup
Lots Less Time and Hassle!
Internal Setup Steps
Streamline Internal Setup Steps
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The Three Stages of Reducing Changeovers

• Stage 1 Separating Internal and External Steps.
• Stage 2 Moving External Steps Out of the
  Changeover.
• Stage 3 Streamline All Aspects of Changeover

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Stage 1Separate Internal and External

• What are all the steps that can be done before or
  after the setup?

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Stage 2Convert Internal to External

• Get and prepare tools and tooling before the
  setup.
• Get materials and supplies ready before the setup
• Make adjustments quickly before starting the
  machine
• Put tools, tooling, etc. away after the setup
• Standardize all this

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Stage 3 Streamline All Other Aspects

• Use more people.
• Develop Function Checklists Check to make sure
  everything works.
• Use quick-release fasteners instead of bolts and
  nuts.
• Use locating pins and holes to eliminate
  adjustments.
• Use standardized tools and tooling whenever
  possible.
• Apply 5S and Visual Factory. Make indexes,
  adjustments, marks very visible.
• Use checklists to avoid omission.
• Use designated carts to help organize tools.

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How We Will Analyze Setups

• Videotape or observe the setup
• Review video or observation sheet and describe
  the steps
• Analyze each step Internal or external? Move
  internal to external.
• Streamline everything else.