Professional Documents
Culture Documents
Setup Reduction
Inventory Reduction
Storage space must be supplied for the
maximum inventory conditions.
Switching from a one-month lot size to a
one-day lot size reduces the required
inventory space by 97%.
Quality Improvement
Quality problems and defects related to
the setup process are reduced because:
Setup errors are decreased
Trial runs of the new part are eliminated
Setup Definitions
Setup time
The elapsed downtime between the last production
piece of part A & the first good production piece of
part B.
Internal setup
That part of the setup which must be done while the
machine is shut down.
External setup
That part of the setup which can be done while the
machine is still running
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Summary
Setup reduction is a powerful tool which
improves a plants ability to provide
customer satisfaction while better utilizing
its assets
Readily adopted by a plants
manufacturing team because they are
easily implemented, have relatively low
cost, and provide quick relief to the
tedious drudgery of long setups.
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P (Preparation)
Actions performed to support the changeover
process
Ensures all parts, tools, and dies are located in
their proper locations before and after a
changeover has occurred
Includes both transportation and storage of
these items
The quality of the materials and tooling being
used must be verified
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Centering
Aligning
Dimensioning
Adjusting temperature and pressure
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Converting Internal to
External Setup
Re-examine operations to see if any steps
were mistakenly assumed to be internal
Analyze ways to convert internal steps to
external
Move required materials and tools to the
workstation prior to the start of changeover
Remove previous tools and materials after
the changeover is completed; or, use
separate material handlers for the task
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Standardize Function
Where possible, standardize:
Sizes and dimensions of all machine parts and tools
Functional elements of tooling, fixtures, molds/dies, etc.
Standardization requires uniformity necessary for setup
operations
Clamping
Centering
Dimensioning
Expediting
Grasping
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Eliminate Adjustments
Settings vs. Adjustments
Settings occur when the position of a limit switch
is changed
Adjustment occurs when the limit switch is
tested and repeatedly adjusted at a new position
Adjustment can be eliminated if a gauge is used to
precisely determine the correct position of the
limit switch
Use dial gauge or numerical control device for
greater precision
Use calibration markings on the machine
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Mechanization
SMED is an analytical approach to setup
improvements
Only one component of the SMED
process
Most costly technique for reducing
changeover times
Use only after all other techniques have
been implemented
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Summary, Part II
Increase availability/up-time
Create additional throughput at no cost
Standardize the changeover process
Promote buy-in from employees
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Establish a Baseline
Baselines are best established using video
of the existing process:
Visually depicts the process
Permits multiple viewings to study the
process
Retains objectivity
Gate-to-gate view ideal
Document results in a worksheet
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Adjustment Waste
Effort to get process stabilized making good
outputs
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External Waste:
Expends resources
Reduce human effort and walking
Examine the 5Ss
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Commit to Continuous
Improvement
Similar to Kaizen, never quit reducing
changeover times
Select different team members
Expand the scope of team members to
include:
Equipment manufacturers
Software developers
Suppliers of information or materials
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Summary
Majority of initial setup reduction activities
yield 25% to 75% reduction in internal
changeover time with no capital invested
Follow a step-by-step process
Utilize teams
Commit to continuous improvement
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