Set-up reduction

Setup Defined

Focus is placed on the time between parts because it is a period of non-value added time. In other words, the equipment is idle and not producing parts.

Internal - External

Objective: Move internal to external, improve both.

Set-up Categories

Foresight

• Planning / Preparation
• Pre-kitting
• Tools
• Gages
• Material
• Point of use storage

Attachment

• How are fixtures and tooling currently attached?
• What other type of attachment devices can be used?
• Toggle clamps
• Cam action clamps
• Auto clamps (include mistake-proofing devices)
• Hook clamps
• Swing clamps
• Quick Acting Clamps
• Swing “C” washers
• Swing bolts
• Quarter turn screws
• Wedges
• Pear shaped / tear drop slots

Setting Conditions

• How is the fixture or tooling positioned?
• What can be used to eliminate setting conditions?
• Locating adapters
• Pins
• Rails
• Notches

Trial Runs

• How do we establish the starting point today?
• What can be done to eliminate trial runs & adjustments?
• Standardized fixturing
• Standardized tooling
• Guide block
• Template
• Alignment marks

Improvement

Training

Training is completed in three areas:

Importance of set-up improvements to increase speed, improve quality, reduce cost, and lower inventory.

Conceptual stages underlying a typical set-up operation & the four phase implementation approach.

Actual examples from manufacturing using video tape and slides demonstrating these concepts and approaches.

During this phase, equipment is usually selected for analysis.

Records

We observe and document existing set-up procedures using a video camera.

We Analyze all work efforts.

We Identify short-term solutions that could be realized with procedural changes, modifications to existing fixtures, and minor investments in tooling.

1. Move as much internal to external time by arrangement of activities and fixtures.
2. Minimize internal and external time by: pre-kitting tooling and fixtures, improving attachment operations, reducing or eliminating adjustments, and organizing the work place.
3. Document improvements and develop procedures & checklists describing proposed activities.

Application

Make minor modifications to the existing fixtures.

Additional tooling to remove attachment from internal to external.

Standardize tooling.

Document time savings.

For example:

• Slots in fixture and T-Bolts reduce attachment time.
• A new part holder reduced the time required to load and unload parts to fixture. Swing hook eliminated the need to remove nut from bolt.
• Extra set of slides allow detach & attach to be completed on external time.

Continuous Improvement

Longer term suggestions

Modifications which may require more investment (money and time)

More complicated improvements

• Design and fabricate new work holding devices that incorporate cassette type inserts.
• Design and fabricate a cart for quick removal & loading of fixture.
• Develop checklist that describes all tools, holders, and gages required. Create kits for all machines and train all people.

Benefits

• Lower throughput time
• Ability to satisfy customer demand
• Greater Flexibility
• Reduction in Inventory
• Increased throughput
• Greater capacity
• Less resources
• Reduced complexity
• Reduced operator dependency
• Improved quality
• Reduced tooling costs

• Synchronize assembly to fabrication
• Shorter production cycle
• Quicker response to demand changes
• Reduced floor space