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Setup Reduction -- Creating More Production Time

Dr. Richard A. Wyskrwysk@psu.edu

http://www.engr.psu.edu/cim

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Readings

• Singo Shingeo, A Revolution in Manufacturing-The SMED-Single Minute Exchange of Dies-System, Productivity Press, 1981.

• Chapter 18 of Computer Aided Manufacturing, Wang, H.P., Chang, T.C. and Wysk, R. A., 3rd Edition (2004 expected) http://www.engr.psu.edu/cim/active/ie450ho1.pdf

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Make it better!Make it faster!

Make it cheaper!

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Objectives• To be able to identify internal and external

process elements• To be able to apply methods improvements

techniques to manufacturing• To calculate/measure the various

Production Time Elements• To be able to apply the techniques of set-up

reduction

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ExerciseReadiness Assessment Test A.K.A. RAT

AS A INDIVIDUALAS A INDIVIDUAL, prepare a justification of reducing set-up time.

• What is the value of reducing the set-up time?• How can set-up reduction activities be justified?• What are the two type of elements of set-up?

Open Book / Open Notes

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How long does it take to produce something?

It is not unusual for the processing time to be a very small part of the time required to make a component.

•Order materials

•Accumulate parts

•Setup machine

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JIT -- Speed is everything!

Some Just in time modelsBuying breadBuying milk

Buying “take-out”

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In Industry

Between .05% and 5% of the time Value is being added to a product

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What are the Value added activities at PSU Inc.?

Receiving -> Material handling ->

Machining -> Assembling ->

Packaging

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Are we really adding value

What percent of the time are the machines producing good product?

What percent of the time are the moving and setting up?

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Producing a product

Production time (per lot) =

setup time (per lot) + manufacturing time (per lot)

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Producing a product

Manufacturing time (per piece) =

material handling and locating time (per piece) + manufacturing time (per piece)

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Simple CNC Example

• New batch of parts arrives– Change over tools for the batch– Set offsets for new tools– Load NC program– Validate

• Run parts– Load part onto machine– Cycle start and wait– Unload and visually inspect (adjust if necessary)

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Graphically it looks like

TOTAL TIME TO PRODUCE A LOT OF PRODUCT

SETTING UP THE MACHINE

RUNNING THE MACHINE AND OFF-LINE MEASUREMENT

This can be > 30% of the TOTAL TIME TO PRODUCE A LOT

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A look at SETUP

SETTING UP THE MACHINE

This can be > 30% of the TOTAL TIME TO PRODUCE A LOT

Setup consists of activities that must be performed on the machine(these are called Internal Elements), and

elements that can be performed off-line or while the machine is producing a product (these are called External Elements)

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Rapid Tool Change-over Setup consists of

• Internal Elements - Elements that must be performed on the machine itself

• External Elements - Elements that can be performed “off-line”

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A look at SETUP (cont’d)

SETTING UP THE MACHINE

These External Elements can be completed while the machine is producing good product. For instance, we can clean a die setafter the machine comes up. We can preassemble componentsfor a setup.

Internal Elements External Elements

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A look at SETUP (cont’d)

SETTING UP THE MACHINE

If the External Elements are performed while the machine is producing good parts then we can reduce the TOTAL PRODUCTION TIME by starting production earlier.

Internal Elements External Elements

RUNNING THE MACHINE

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Premise for SMED

Idle time waitingfor materials orother resources Set up time where

machine is downwhile operatorsprepares for nextactivity Processing time - adding value to raw materials

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Graphically it looks like

TOTAL TIME TO PRODUCE A LOT OF PRODUCT

SETTING UP THE MACHINE

RUNNING THE MACHINE AND OFF-LINE MEASUREMENT

Production Time gained

SAVINGS

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Premise for SMED

Idle time waitingfor materials orother resources Set up time where

machine is downwhile operatorsprepares for nextactivity Processing time - adding value to raw materials

Methods improvements

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Exercise (5 minutes)

As an individual, describe a process that you know well (from work, food preparation, office activities…)

Identify the internal and external elements for setup or work changeover.

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Methods Improvement

• Standard ways to improve setup efficiency– Power tools– Collets and quick-change fixtures– 2nd set of fixtures and tools– Setup layout– Setup accumulation

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Examples of Improved Methods

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Make the tool part of the screw device -- you don’t need a tool, and this will save time in disassembling and reassembling the tooling and fixturing!

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Reduce the amount of turns required in order to activate the screw.

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Reduce the amount of screw turns and eliminate the tool!

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Areas with potential benefit

• Screws and screw fasteners• Tedious manual activities• Power tools can be appropriate• Connectors• Others????

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Currently changeover is done with these tools

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Currently changeover is done with these tools

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How about power tooling?

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How about cordless power tooling?

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SMED is employee driven

• Train Area supervisors and operators• Some implementation with outside

consultant• Most implementation within your company

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Questions?