Setup Reduction Removing the Rocks

Transcription

1 Setup Reduction Removing the Rocks Paul W. Critchley, President, New England Lean Consulting PRESENTED BY

2 Why is Setup Reduction Important? Water (inventory) covers up the rocks: Lack of standard work No PM or TPM plan Poor / no 5S Hidden factory / rework Poor quality Machines not running = parts not being made Overhead still exists Direct labor still gets paid Customers still want their parts Is the biggest bang for your buck Cycle time optimization comes later

3 Setup Defined A setup is the activity necessary to prepare a machine to produce a part We measure setup time as the total elapsed time between production of the last good part of type A and the first good part of type B Tools, fixtures, materials, adjustments Start of B run; end of setup A A A B B B B B B End of A run; time zero

4 Benefits of Setup Reduction 1. Batch sizes can be reduced (or eliminated) 2. Ability to produce a greater variety of parts 1. Greater schedule flexibility 2. Improved customer service 3. Reduce in process inventory 4. Reduce occupied floor space 5. Increase productivity 6. Reduce cost 1. Less setup waste 2. Better overhead absorption 3. Less likely to have large scale quality problems 7. Is an enabler for other Lean tools 1. Remove rocks, THEN lower water 2. Avoid the Sense of Urgency pitfall Typical factors of a setup

5 Benefits of Setup Reduction Let s look at a typical week s production need example: Assumptions: 440 minutes available/day (7.3 hrs) You make & sell 6 different models Cust. Demand: 1900 pcs/day Cycle time: 12s/piece Results: Will take 6 days to cycle through all models Need 6 days worth of inventory of each That s 11,400 $20/pc, that s $228,000 worth of inventory 5

6 Benefits of Setup Reduction Let s look at a typical week s production need example: Assumptions: 440 minutes available/day (7.3 hrs) You make & sell 6 different models Cust. Demand: 1900 pcs/day Cycle time: 12s/piece Results: 83% reduction in inventory and that s $38,000 in inventory 6

7 The 2 Elements of Setup Internal Setup Those setup operations that must be performed while a machine is idle or stopped, such as mounting or removing tooling External Setup Those setup operations that can be performed while a machine is running, such as transporting tooling to and from storage

8 Setup Reduction Process 1. Document all setup steps 2. Identify Internal vs. External operations 3. Separate External/Internal operations 4. Convert Internal operations to External operations 5. Optimize setup steps

9 1. Document all setup steps Record a video to watch later Can watch multiple times You ll see things you once missed Helps document Current State Ensures no steps are missed or assumed

10 2. Identify Internal vs. External operations Study the video in detail Identify all the tasks Number the tasks in sequence Measure the time for each task Divide the tasks in internal or external Must include crossfunctional team Changeover Analysis Chart Cell: # Task Time (s) Internal External 1 Lower Ram 20 X 2 Prep to remove bolts 30 X 3 Remove upper bolts 15 X 4 Remove lower bolts 20 X 5 Raise Ram 35 X 6 Turn press off 5 X 7 Move bolsters 15 X 8 Remove lower bolts 15 X 9 Attach die cable 1 20 X 10 Attach die cable 2 20 X 11 Hoist die 20 X 12 Move die 10 X 13 Position die 45 X 14 Tighten upper bolts 15 X 15 Tighten lower bolts 20 X

11 3. Separate External/Internal operations Besides making sure that tools and materials are available, we must verify that they are all correct and usable: Are gauges calibrated (when applicable)? Was the correct raw material delivered? Are tools in good shape? Have outstanding repairs on molds and dies been completed? Consider adopting a standard work loop to include tool room checks after dies/tools are used and before they are stored All of these can be done Externally Waiting until the machine is idle is the wrong time to find out something is missing or damaged! Total Changeover Time Internal Changeover Time Identify Separate Convert Optimize

12 4. Convert Internal to External There are two ways to convert internal setup to external setup: Set the operating condition in advance Standardize the functions of setup steps Setting conditions in advance includes such activities as: Pre heating of dies and molds Preloading/offline editing CNC programs Pre assembly of fixturing Standardize the function includes such activities as: Commonize tool and fixture sizes Commonize equipment Southwest Airlines Identify Separate Convert Optimize Challenge: Ask yourself what it takes to get to a normal operating condition, then ask how you can get to that condition before the setup even begins

13 4. Convert Internal to External Pursue External setup reduction to free up time for other things: Cross training Running multiple machines Help elsewhere Continuous improvement activities

14 5. Optimize setup steps Splitting setups between 2 (or more) operators can dramatically speed up setups Safety can be maintained through a variety of ways including interlocks Train and document via Standard Work Identify Separate Convert Optimize Changeover Analysis Chart Cell: # Task Time (s) Internal External 1 Lower Ram 20 X 2 Prep to remove bolts 30 X 3 Remove upper bolts 15 X 4 Remove lower bolts 20 X 5 Raise Ram 35 X 6 Turn press off 5 X 7 Move bolsters 15 X 8 Remove lower bolts 15 X 9 Attach die cable 1 20 X 10 Attach die cable 2 20 X 11 Hoist die 20 X 12 Move die 10 X 13 Position die 45 X 14 Tighten upper bolts 15 X 15 Tighten lower bolts 20 X Operator 1 Operator 2

15 5. Optimize setup steps Quick clamps can reduce or eliminate turns of screws and bolts, since only the last turn tightens and the first turn loosens Use pear shaped holes Use cam locks Use attached c washers Use fewer bolts

16 5. Optimize setup steps Quick Change collets allowed for a 13 second C/O Gradually moved from high WIP To Kanban between cells To reduced Kanban levels To eventually being made to order Process took 1 year Gradually Lowered the water level

17 Summary Setup Reduction is a powerful tool - if used diligently we can get to 1/60 of the original setup External elements are done while the machine is running Internal elements are done while the machine is stopped Setup Reduction can allow us to progress towards one piece flow Setup Reduction is a methodical process utilizing other Lean tools like 5S and Standard Work All adjustable settings can be misadjusted Positive positioning & alignment is the only certain way to assure quality The best adjustment is NO ADJUSTMENT!!!

18 Thank you New England Lean Consulting Twitter Website: