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IE 427- Lean Production Systems Spring 2014
Department of Industrial & Systems Engineering The
University of Tennessee 1
Dr. Rupy Sawhney
Quality
People make fewer mistakes when they follow simpler
procedures.
Mistakes made during setup have the potential to affect the
entire batch.
With standardized setup procedures, trial and error adjustment
can be eliminated.
Costs
When changeover times are small, smaller batches may be produced
more frequently.
Reduction in WIP and finished goods investment
Reduction in required labor hours and skill level of
employees
Reduction of scrap generated as a result of setup procedures
Flexibility
The ability to more readily meet customer demand is
enhanced.
Worker Utilization
Simple setups do not require special skills and may be done by
operators, thus
reducing their idle time.
Setup technicians may then be used to address higher level
concerns, such as
technically difficult setups or continued
setup improvements.
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IE 427- Lean Production Systems Spring 2014
Department of Industrial & Systems Engineering The
University of Tennessee 2
Capacity and Lead Times
When current capacity is nearly filled, reduced setup time is a
low cost alternative
to overtime or equipment acquisition.
Make to Order becomes possible in traditional Make to Stock
businesses.
Lead Time is diminished due to decreased lot sizes and a
reduction in time spent
waiting for setups.
Process Variability
Each setup is itself a process with several discreet steps.
Therefore, there is variability inherent in looking for tools,
tearing down old fixtures, building up
new ones.
When these steps are ill-defined, the potential for variability
is increased.
The ultimate setup reduction is the elimination of the setup
entirelythis then eliminates the setups contribution to overall
process variability.
Reduced setup times allow
More Setups per period
Smaller Batches
Increased Flexibility
Improved Response Time
Increased Time Available for Production
But with all these benefits,
why are setups neglected?
Setup reduction takes dedicated effort frompeople who know the
equipment and operation
best: machine operators and setup people.
In many cases these individuals have never been asked to do
analysis, contribute
suggestions, or take responsibility for anything
beyond their job descriptions.
There is often a preference towards the purchase of new
equipment rather than
the improvement of existing equipment.
There may be reluctance to improve equipment that one would like
to see
replaced at a future date.
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IE 427- Lean Production Systems Spring 2014
Department of Industrial & Systems Engineering The
University of Tennessee 3
People with technical backgrounds or who may have had exposure
to automation
often come up with complicated or costly
solutions which are dismissed as
impractical.
(In fact, however, most improvements can be achieved through
relatively simple means.)
Improvements to machines and tools often require the skills of
machinists and tool
makers, who are usually busy fixing
broken machines.
Setup reduction requires these people be allocated time for
setup projects.
Reducing setup on just a few machines or processes has little
impact, so individual
setup projects are hard to justify
Setup reduction cannot be achieved on all fronts simultaneously,
and it takes time
before benefits are felt globally.
Maximize the transfer of responsibility to the operators.
Minimize machine downtime due to setups.
Abolish setup.
NOT to abolish setup specialists. Their skills should be used in
other activities such as Standardization of setup activities.
Modification of procedures, tools, and fixtures to improve
setups.
Methodology
Single Minute Exchange of Dies
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IE 427- Lean Production Systems Spring 2014
Department of Industrial & Systems Engineering The
University of Tennessee 4
SMED methodologies were developed in Japan by a consultant to
Toyota, Shigeo Shingo.
Though developed primarily for metal-working processes in the
automotive industry, SMED is
now applied universally to any system
encompassing a processing station.
Type 1 Retrieving, preparing, and checking materials, tools,
etc. before the setup; cleaning the machine and workstation;
checking and returning tools after the operation is completed
Type 2 Removing tools, parts, etc. after completion of the
last
lot; mounting tools, parts, etc. prior to the next lot
Type 3 Measuring, setting, and calibration
Type 4 Producing and evaluating test product
Stage 1: Identify Internal and External Steps.
Internal: Must be performed while the machine is stopped.
Equivalent to downtime.
External: May be performed while the operation is running.
Most Type 1 Setups are external.
Type 2,3, and 4 are generally internal.
The main focus of setup time reduction is on
internal setupsNOT on total setup time. While reducing total
setup hours is desirable,
it is not of primary importance.
Stage 1, Step 1: Analyze the existing setup.
Detailed analysis of the procedure. May involve the use of
stopwatches, video taping, interviewing setup personnel
Stage 1, Step 2: Classify the steps in the setup procedure.
Determine whether steps are internal or external. Determine
whether steps might be eliminated.
Sample SMED Worksheet
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IE 427- Lean Production Systems Spring 2014
Department of Industrial & Systems Engineering The
University of Tennessee 5
1) Breaks setup down into discreet steps, or
elements.
2) Classifies whether the steps as they exist
are Internal or External.
3) Accounts for time.
4) Accounts for the individual performing
the setup.
Stage 2: Convert internal steps to external steps.
Readily converted steps include:
Heating dies or tooling
Locating tools or fixtures
Other preparatory steps
Referring again to the example, observe that all steps are done
after the machine is stopped.
Steps 1 and 2 (Check in, die transfer) could be done while the
machine is still running.
Step 4 (return old die to storage) could be done after the
machine resumed production.
Stage 3: Improve all aspects of the setup operation.
Converting internal steps to external steps reduces setup time
considerably, although usually not enough to be in the single
minute range (
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IE 427- Lean Production Systems Spring 2014
Department of Industrial & Systems Engineering The
University of Tennessee 6
The primary goals for stage 3 are:
Setups will now take less than ten minutes. ?
Setups involve no more than a single touch procedure.
OTED: One touch exchange of dies.
Implement checklists of standard setup procedures.
Equipment malfunctions that make themselves known only when they
are about
to be used will increase internal time.
Therefore, regular equipment checks and
repairs must be performed.
Daily setup schedules ensure that tools and personnel are
available when they are
needed.
Parallel Setup Tasks
Internal setups can sometimes be improved by having multiple
workers doing
setup tasks simultaneously.
Ideal for large
machines
where setup entails a
good deal of walking.
A multiple person setup is a team effort, meaning individuals
scattered throughout the plant must be assembled.
Workers functioning in parallel must coordinate actions.
Danger of one worker starting a step which may injure
another.
Not a simple technique, and therefore only a good solution for
short term.
Much internal setup time is spent securing fixtures and
materials to machines
Bolts are the most common method of attachment, though very
inefficient.
Attachment activities may be simplified by: Reducing the total
number of fasteners used
Standardizing the size of fasteners so that only one tool is
necessaryeliminate searching for the right tool!
The longer the bolt, the more turns necessary to tighten it.
However, in reality it is only
The LAST turn that tightens a bolt.
The FIRST turn that loosens a bolt.
Given this reality, setup time may be
reduced through the use of one-turn bolt
attachments.
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IE 427- Lean Production Systems Spring 2014
Department of Industrial & Systems Engineering The
University of Tennessee 7
U-Shaped Washers The washer has a hole bigger than
the bolt and is slipped underneath
prior to tightening.
Pear-shaped holes Fixture may slide into place and
then be fastened.
Split-Thread Bolts Drops easily into hole and may be
tightened with just 1/3 turn.
T or L-shaped Heads When high torque is not required,
this fastener type eliminates the
need for a tool
Parts and fixtures may also be held in place by standard sized
holders and pins.
Simple clamping devices are particularly useful in turning
machining setups into one-
movement procedures
Most setups include a period of adjustment, no matter how
skilled the operator.
Adjustment generally incorporates a run-measure-adjust cycle
that must be repeated many times.
Such trial and error procedures are often the most time
consuming part of the internal setup procedure.
What if trial and error could be eliminated, replaced by a
single motion?
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IE 427- Lean Production Systems Spring 2014
Department of Industrial & Systems Engineering The
University of Tennessee 8
There are 2 types of adjustment that must be approached in
different ways.
Type 1 involves the setting of parts and fixtures to the correct
position.
Type 2 involves the right combination of speed, pressure, feed
rates, temperatures,
and other adjustable variables.
When dies and fixtures are of varying sizes, the use of shims
and inserts will greatly reduce
spatial adjustments.
Shims and inserts may be fabricated and then stored with dies to
be used as needed.
Cassette-type holders may also be employed to similar
effect.
Here dies of varying heights are
accommodated by shims.
Cranks, handles, levers, switches, and other adjustable
mechanisms are common to many machines.
Positioning of these mechanisms is often a source of
delayparticularly in cases where the mechanism itself or the
associated gauge may be dirty or broken.
Correct combinations of settings, when found, should be written
down and stored.
All mechanisms should have calibrated scales.
Observe the mechanism below. With the configuration on the left,
it would be very difficult to
find the precise setting without trial and error. With
scales such as those on the right, it becomes much
easier to set the mechanism to values specified in a
checklist.
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IE 427- Lean Production Systems Spring 2014
Department of Industrial & Systems Engineering The
University of Tennessee 9
Stage 4: Abolish setup.
The ULTIMATE setup improvement beyond OTED. But how are setups
eliminated?
1) Reduce or eliminate differences between parts.
- Fewer or no differences means fewer changeovers.
- Design-based approach to setup reduction.
- Determine what parts can be standardized and used
on all or many products.
- Group technology.
2) Make multiple kinds of parts in one step.
- For example, form two kinds of parts from a single
stroke of a press rather than forming the two parts
sequentially with a setup in between.
3) Dedicate machines to making just one item.
- If only one item is ever made on a machine, then
obviously that machine never needs a changeover.
- This approach is clearly only practical when the cost of
acquiring new machines is relatively inexpensive when
compared to the cost of performing setups.
It should be noted that in order to abolish setups it is not
necessary to have gone
through the first three stages.
The alternatives for abolishing setup may be doable in short
order.
Storage Everything needed for setup should be as
close as possible to the setup site.
Items used frequently on a machine should be kept at that
machine.
When the number of different setup items is large, space
constraints may dictate that they be stored together. In such
cases, color coding helps to facilitate quick removal.
Kitting
When all items needed for setup are available in one place at
one time there is no time lost searching.
Kits may be stored on
carts and kept close
at hand
Carts should be
partitioned and visually
differentiable
Material Handling equipment should be right-sized for the job.
Use of forklifts, which require time to arrive on
site, should be minimized if possible
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IE 427- Lean Production Systems Spring 2014
Department of Industrial & Systems Engineering The
University of Tennessee 10
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IE 427- Lean Production Systems Spring 2014
Department of Industrial & Systems Engineering The
University of Tennessee 11
QUESTIONS