Ensuring Value (Part 2)

1
Ensuring Value(Part 2)

• Quick Changeover / Set-up Reduction

2
Set-Up Reduction

• Set-Up Reduction Introduction
• Effect of Set-Up Reduction
• The Four-Step Method
• Implementing Set-Up Improvements

RD010402
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Total Cost is Key (review)

• In Lean Manufacturing, we focus on reducing waste
  in our processes, by focusing on
• Productivity (pieces per hour cycle time
  schedule attainment)
• Quality (scrap and rework fit with customer
  needs)
• Downtime (equipment uptime availability of
  qualified personnel)
• Speed (on-time delivery lead-time
  order-to-delivery)
• Cost (to produce each piece overtime expediting)

• The Seven Deadly Wastes
• Over-producing
• Waiting
• Over-processing
• (Too Much) Inventory
• (Unnecessary) Motion
• Defects or Rework
• (Excessive) Transportation and Materials
  Handling
• Plus One More Underutilized (Human) Resources

4
Cycle Time Barriers (review)
Multi-Step Process
Operation 1
Operation 2
Operation 3
Operation 4
Output
Input
Cycle Time

• Set-up Events are one of the key barriers to fast
  cycle times.

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What Is Set-Up Reduction?

• Set-Up Reduction is a process in which the time
  and effort for equipment changeover is reduced to
  an absolute minimum without adversely affecting
  quality.
• Two components of set-up reduction that must be
  addressed are
• Machine down time or set-up/changeover time
• Machine ramp-up time (i.e., making adjustments to
  meet specs)

Total Time Lost to S/U and C/O
Job 1
Production
Job 2
Downtime
Ramp-up time
6
Set-Up Time Defined
Last Good Product of Run
First Good Product(s) of Run
Preparation
Actual S/U
30
Adjustments
5
A
B
15
Trial Runs
50
Set-Up Time

• Set-Up Time is the length of time between the
  last good product of a production run to the
  first good product(s) of the next production run

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Components in the Set-Up Process

• Preparation
• Obtain work order and instructions
• Gather and return tools
• Retrieve and return change parts
• Clean machine
• Check materials
• Clean work areas
• Set-Up
• Change machine / equipment hardware
• Mount and remove dies, tools, blades, etc.

• Adjustments
• Measure / calibrate
• Center dies, tools, blades, etc.
• Modify settings
• Trial Runs
• Adjust after test or 1st piece product is made
• Inspect / measure test piece or 1st piece

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Advantages of Rapid Set-Up Over Typical Set-Up

• Cut scrap and rework risk by 50
• Cut inventory investment by 50
• Able to introduce quality improvements at twice
  the rate (more cycles of learning)
• Able to change the schedule twice as often to
  meet changing customer demands
• Able to introduce design changes at twice the
  rate
• Increase available floor space

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Four-Step Set-Up Reduction Method

1. Document Set-Up and then Separate Events into
   Internal and External
2. Convert Internal Events to External Events
3. Streamline Internal Set-Up
4. Eliminate Adjustments

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Step 1 of 4
STEP 1 Document the set-up and separate events
into internal or external
D, M
Step 1 is done first to attain benefits quickly
STEP 3 Streamline internal events (Simplify,
Reduce, Eliminate)
STEP 2 Convert Internal to External events
STEP 4 Eliminate adjustments internal to the
set-up
A, I
I
I, C
Corresponding DMAIC phase for a stand-alone
Set-Up Reduction project
xx
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Step 1 Goal of Step 1

• Goal Document the set-up and separate into
  internal and external events
• Internal Set-Up is an event that must be
  performed while the equipment is down (not
  running or producing parts).
• Exchanging dies/fixtures in the machine
• External Set-Up is an event that may be performed
  while the equipment is producing parts.
• Retrieving drawings, tools, hardware and parts
• Loading programs

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Physical Flow (review)

• Physical Flow represents the path of movement a
  product family follows through a facility. The
  flow of the material (or a worker) is traced
  though the facilitys layout, showing the path
  and distance traveled while completing a task.

• Effects of Poor Physical Flow
• Long process cycle times
• Excess materials handling or wait times
• Damage to goods in-transit
• Increased chance for injuries
• Poor visibility to actual production
• Typical Causes of Poor Physical Flow
• Lack of materials handling equipment
• Long distances between work stations
• Large loads, batches or transfer sizes
• Un-ergonomic placement of equipment
• Poor process design or task order

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Step 1A Area Layout Diagram (a.k.a. Spaghetti
Diagram)

• Document relative position of cabinets, tools,
  dies/fixtures, hardware, etc., in relation to the
  set-up activities
• Record the movements of the operators/set-up
  personnel throughout the set-up activities
• Track each foot traffic movement of key
  operators/set-up personnel to determine the total
  distance traveled during the operation
• Key in gaining buy-in (especially from the
  operators) to the improvement suggestions

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Step 1ACreating and Using the Area Layout
Tool/Die Fixture Room
Hardware Cage
Hand Tool Cabinet
Punch Press 1465
Controls
Tool Carousel
Note To enhance area layout readability,
consider numbering each traffic line and / or use
multiple area layout pages
Quality Control
Production Control
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Step 1AArea Layout (Example)
Does this appear efficient?
This set-up could probably be streamlined with
better storage and location of needed items!
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Step 1A 1BSet-Up Documentation Worksheet
ITEM _____________________________
See copy in Excel format within Appendix A
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Step 2 of 4
STEP 1 Document the set-up and separate events
into internal or external
STEP 3 Streamline internal events (Simplify,
Reduce, Eliminate)
STEP 2 Convert Internal to External events
STEP 4 Eliminate adjustments internal to the
set-up
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Step 2 Goal of Step 2

• Goal Convert internal set-up events to external
  events
• Re-examine internal events from Step 1 and verify
  they are actually internal
• Convert any internal set-up events to external
  set-up events using focused, engineered methods
• Change set-up procedures to reflect only internal
  activities
• Develop external activity procedures
• Use Brainstorming tools abundantly to gather and
  build good ideas

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Step 2 Improvements Worksheet

• The Improvements Worksheet is used to document
  all improvements to the set-up.
• The worksheet is used to develop action plans
  (Continuous Improvement To-Do List) and work
  orders that will initiate improvement
  implementation.
• The reduction in set-up time is calculated on
  this sheet as improvements are implemented over
  time.

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Step 2 Improvements Worksheet (Example)
See copy in Excel format within Appendix A
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Step 2Organize for Set-Up

• Fact Vast amounts of set-up time are lost due to
  searching for set-up hardware and set-up
  information.
• Set-Up Hardware
• Tools
• Fixtures
• Nuts and Bolts
• Clamping Devices
• Measuring Devices
• Set-Up Information
• Data (Tool and Machine Settings)
• Procedures
• Drawings

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Step 2Organizing Set-Up Hardware

• Set-Up hardware should be organized by either
  specific set-ups or by specific hardware or
  workstation.
• Set hardware should be stored near the
  workstation.
• The storage locations should be labeled as to
  what set-up or component is stored at that
  location.
• The fixtures and tools should be organized to
  easily determine if components are missing prior
  to set-up (shadow-boards).
• Set-Up data for machine settings, tooling
  settings and shim sizes should be placed on
  designated charts and stored near the
  workstation.
• Detailed set-up procedures should be stored near
  the workstation.

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Step 2Applications of Step 2

• Checklists
• Check Tables or Shadow-boards
• Battle Plans
• Functional Checks
• Improving Transportation

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Step 2Checklists

• Checklist of parts and steps required in set-up
• Names of Tools
• Specifications
• Identification of Change Parts (nozzles, pipes,
  hoses, etc.)
• Settings (temperature, pressure, location, etc.)
• Numeric Values for Measurements

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Step 2Checklist (Example)
Part 432543

• Press P-10
• Die 274
• Die Location Shelf 4
• Platen 42
• Platen Location Shelf 5
• Tools Die Cart, 1/4 and 1/8 Allen Wrench,
  Screwdriver, 1/4 Open-Ended Wrench
• Settings Ram 12.50

• External Events
• Review check table
• Retrieve change parts
• Tools clean and in working order
• Change parts clean and in working order
• Functional checks completed

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Step 2Check Table or Shadow-Boards

• Provides "quick check" for tools.
• Tools are placed over drawings or outlines drawn
  on check table or shadow-board.
• Missing tools are easily identified.
• Tools should be retrieved during external set-up
  time.

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Step 2Battle Plans

• Developed daily
• Everyone involved in set-up and operation must
  know battle plan

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Step 2Functional Checks/Improving Transportation

• Functional Checks
• Used in conjunction with checklist and check
  table to determine if all set-up parts, tools,
  etc. are in perfect working order
• Must be performed externally
• Improving Transportation of Change Parts
• All transportation of change parts must be
  performed externally
• Make use of a set-up tool cart, pail, tray or belt

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Step 2Die Retrieval for Punch Press

• OLD - 35 min

NEW - 11 min
Stop press - begin internal set-up
Remove die from press
External
11 min
Transport die to storage area
35 min
Retrieve new die from storage area
Transport die to press
External events for the next run are to be
performed while the prior part is being run.
Place die on press
Continue set-up
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Step 3 of 4
STEP 1 Document the set-up and separate events
into internal or external
STEP 3 Streamline internal events (Simplify,
Reduce, Eliminate)
STEP 2 Convert Internal to External events
STEP 4 Eliminate adjustments internal to the
set-up
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Goals of Step 3

• Goal Streamline internal set-up by streamlining
  the internal set-up steps by
• Simplifying Movement
• Reducing Movement
• Eliminating Movement

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Step 3Applications to Streamline Internal Set-Up

• Reduce / eliminate need for hand tools
• Reduce / eliminate nuts and bolts, hex nuts, etc.
• Replace with quick fastening / releasing devices
• Single-motion securing
• U-slot method
• Pear-shaped hole method

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Step 3 Securing Method Exercise

• Before Traditional Securing Method
• 4 bolts per die
• 12 turns per bolt to secure
• 4 bolts/die x 12 turns/bolt 48 turns/die
• 0.05 min/turn x 48 turns/die 2.4 min/die
• 2.4 minutes to remove 2.4 minutes to secure

Bolt with 12 Threads
4.8 minutes
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Step 3 Securing a Die, Pear Shaped Hole Method

• After Pear-Shaped Hole
• 4 bolts per die
• 1 turn per bolt to secure
• 1 turn per bolt to remove
• 4 bolts/die x 1 turn/bolt 4 turns/die
• 0.05 min/turn x 4 turns/die 0.2 min/die
• 0.2 min to remove 0.2 min to secure

Bolt with 12 Threads BUT only one turn to secure!
0.4 minutes
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Step 3Securing a Die Comparison

• Traditional 4.8 Minutes
• Pear-Shaped Hole 0.4 Minutes

• Internal Set-Up Time
• Streamlined by 4.4 minutes
• Reduced by 92

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Step 3Nut Bolt Improvement Methods
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Step 3One-Turn Procedures
NEW 1.6 min
OLD 18 min
8 bolts to be removed
0 bolts removed 8 half-turns to loosen

• Eliminate lost nuts, bolts, different-size nuts
  and bolts

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Step 4 of 4
STEP 1 Document the set-up and separate events
into internal or external
STEP 3 Streamline internal events (Simplify,
Reduce, Eliminate)
STEP 2 Convert Internal to External events
STEP 4 Eliminate adjustments internal to the
set-up
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Step 4Goal of Step 4

• Goal Eliminating Adjustments
• The elimination of adjustments and trial runs by
  turning intuition and guessing into fact and
  settings.
• Elimination means elimination not reduction
  in the time required to perform adjustments.

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Step 4Test Runs Are Typically 50 of Set-Up Time
Measurementsand Settings 15
Set-Up 5
Test Runs 50
Preparation 30
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Step 4 Adjustments and Test Runs

• Adjustments and test runs are normally due to
• Inaccurate Centering
• Inaccurate Settings
• Inaccurate Dimensioning
• Inaccurate or Inadequate Measuring
• Poor Documentation

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Step 4 Eliminating Adjustments

• Abandon reliance on intuition for settings
• Settings as a result of intuition are inexact,
  are rarely replicable, and do not provide the
  required precision as constant value settings
• Convert intuition to FACT
• As long as settings are made based on intuition,
  there is no way to avoid adjustments and test runs

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Step 4 Pin and Place Method on Conveyor Rails
One fixed side plus pre-determined settings on
the other side
Completely variable placement on both sides
Before
After
Screws
Pins
Set
Rail Fixed
Slide Adjust
Slide Adjust
8 Minutes
34 Minutes
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Step 4 Pin Place Method Conveyor Rails
Results

• OLD - 34 min

NEW - 8 min
Loosen screws with 1/4 wrench
Pull securing pins
Slide rails into place using a bottle as the guide
Move rail to appropriately marked width
Tighten screws with 1/4 wrench
Yes
Replace pin
34 min
Start production
Start production
Bottle jam
No
Continue production
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Step 4 Centering Method
Before
After
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Step 4 Centering Method Results
0 Scrapped Parts
Average 2 Scrapped Parts
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Step 4 Cap Sealer Height Setting
Set Screw
Pin
150 cc
SEALER
SEALER
100 cc
50 cc
SETTING
SETTING
No indication of settings for specific bottle
sizes
Indication and slots for each bottle size
10 minute procedure with average 2 to 5
adjustments
30 second procedure with zero adjustments
Up to 5 Bottles Scrap!
0 Bottles Scrap!
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Step 4 Machining Setting Checklist

• Provide vehicle for converting settings based on
  intuition to settings based on fact!

Milling Machine M-25 Setting Checklist