1 Setup Reduction For CNC Principles Copyright 2001.

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Setup Reduction For CNC

Principles

Copyright 2001

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Setup reduction principles:

Definition of setup time Two task types related to setup Three ways to reduce setup time Four steps to setup reduction

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Definition of setup time:

The time it takes to go from making the last workpiece in the most recent production run…

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The time it takes to go from making the last workpiece in the most recent production run…

…to making the first good workpiece (efficiently) in the next production run

Everything that happens while the machine is down between production

runs is part of setup time!

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By our definition:


If you’re running but one workpiece…

…there is no production run

If you have machines dedicated to one job…

…there is no setup

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Much is directly related to setup:

Tear down old setup & put everything awayClean machineMake new setupCutting tool tasks

Assemble, measure, and enter offsets forAssign program zero

Measure position and enter fixture offsetsLoad programVerify programOptimize program

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But maybe some non-productive activities:

Time spent gathering needed itemsHand toolsCutting toolsFixturesGaugesMaterialPaperworkStorage containers

?

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Or maybe some non-productive activities:

Time spent gathering needed itemsPersonal time

BreaksLunchPhone calls

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Or maybe some non-productive activities:

Time spent gathering needed itemsPersonal timeTime spent waiting

For inspectionFor tool crib attendantFor fork lift operator

These are all fair game for your setup reduction program!

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Core tasks:

Time spent gathering needed itemsPersonal timeTime spent waiting

For inspectionFor tool crib attendantFor fork lift operator

Non-productive tasks:

Compare core tasks to non-productive tasks!

One goal will be to find ways to draw

total setup time down to the time it

takes to complete core tasks!

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One more point…

Setup time: the entire time a machine is down between production runs

Cycle time: the time it takes to complete a production run divided by the number of good workpieces produced

Think about it…

…machines are either in setup or running production – there is nothing else!

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Two setup-related task types:

On-line tasks:Tasks done while the machine is down between production runs

Off-line tasks:Tasks done while the machine is in production for the next (or some future) setup

Setup time is the sum-total of all on-line tasks!

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Tasks commonly done while the machine is down

The fewer the people in the CNC environment, the more tasks tend to be done on line

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ProgrammingCutting tool assemblyGathering of hand toolsGathering of fixturesGathering of gauges

Tasks commonly done off line


The more people in the CNC environment, the more that

can be done off line

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Important points:

The machine is down during the performing of on-line tasks

The machine is running during the performing of off-line tasks

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Off-line tasks are affected by lot size and cycle time…

…with small lots and short cycles, there won’t be time to do anything off line!

Even with large lots……if cycle time is short, the operator won’t

have time to do anything during the CNC cycle!

More about off line tasks

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Three ways to reduce setup time:

Eliminate (especially on-line) tasksYou save the amount of time it was taking to perform the task

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Eliminate the taskRemember, given unlimited resources, there

is no task that cannot be eliminated!

Don’t be too quick to give up on eliminating tasks

Ingenuity plays a big part!

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Move on-line tasks off lineAt least the machine is not down during the performance of the task

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Many tasks can be done while the machine is running production

Assumes you have adequate lot sizes, cycle times, and available personnel

Often requires duplications (especially tooling)

Move the task off line

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Facilitate tasksMake it as quick & easy as possible to perform the task

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The easier a task is to perform, the faster it can be done!

Task simplification makes it possible for people with lower skill to perform well

Often the easiest alternative to justify

Facilitate the task

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All setup reduction techniques fall

into one of these three categories!

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Remember – feasibility doesn’t always equal possibility

Your first goal:

Eliminate the task!

If that’s not feasible:

Move the task off line!

If that’s not feasible:

Facilitate the task!

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Regardless of whether you are trying to improve an entire setup…

…or but one task that is performed in many setups…

…there are four basic steps

1) Evaluate current methods2) Brainstorm for improvements3) Assign and implement changes4) Gauge success

Planning form is in your manual

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We’ll show many ways to change the way you make setups

With the goal being to reduce setup time

But some changes may have unexpected consequences

Step one: Evaluate current methods

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You must be able to gauge the impact of any change on your CNC environment!

Since we’re talking about setup time reduction…

…most evaluations will be gauging timeBefore you attempt to improve a

setup task, you must know how

long the task is currently taking!


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The time required to performing a task is directly related to its complexity

Since facilitating (simplifying) tasks is one way to reduce setup time…

…you must also be able to evaluate the complexity of tasks to be improved

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Get everyone’s approvalWatch for unusual behaviorUse a camera with time/date

The best way is to video tape the task…



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…another way is to simply time the task



But it will be much more difficult to evaluate complexity

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Teardown

Work Holding SetupTool Assbly

Tool Meas

Tool Loading

Prog. Zero Meas.

Offset EntryProgram Loading Program Verification

1st Piece Insp.



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What you may find:

A high degree of disorganization!

Your greatest initial improvement may be…

…to get better organized

Organization of hand toolsOrganization of cutting toolsOrganization of fixturesCleanliness of work areaMisplaced items

Poor documentationMinimal engineering supportConflicting methodsNo communicationTooling not available

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Setup reduction form:

1 Setup Reduction For CNC Principles Copyright 2001.

Documents

setup slide

future setup setup time

total setup time

point setup time

setup j

setup reduction slide

new setup

old setup