Setup Time Reduction - Northern Virginia Section 0511 · PDF fileEOQ Assumptions / Computation ... SMED: Basic Principles

Setup Time Reduction

Using: Single Minute Exchange of Die

G.V. Clarke Lean Quality Assoc., LLC

10/22/201

2 1 Copyright-Lean Quality Associates, all rights reserved

In the beginning, there was…STORAGE.

Definitions of TIME

Typical Old procedures /Wastes

EOQ Assumptions / Computation

Improvement process / SMED

Necessary cultural preparation

Basics & Principles

Typical Results

Q & A

www.leanquality.net

10/22/2012 2 Copyright-Lean Quality Associates, all rights reserved

Lean

Definition:

“A systematic approach to identifying and

eliminating waste(non-value-added activities)

through continuous improvement by flowing the

product at the pull of the customer in pursuit of

perfection”

10/22/2012 3 Copyright-Lean Quality Associates, all rights reserved

About Lead Time

“One of the most noteworthy

accomplishments in keeping the price of Ford

products low is the gradual shortening of the

production cycle. The longer an article is in

the process of manufacture and the more it is

moved about, the greater is its ultimate cost.”

Henry Ford, 1926

10/22/2012 4 Copyright-Lean Quality Associates, all rights reserved

Set Up Time

Definition:

“The time between the last good piece off the

current run and the first good piece off the

next run.”

10/22/2012 5 Copyright-Lean Quality Associates, all rights reserved

Historical setup Procedures

Preparation cleaning up completed job

receiving instructions for next job

storing/retrieving tools, parts, materials

checking functionality

Parts removal and attachment

Centering, dimensioning, and setting

tools, dies, jigs, gauges

Trial processing and adjustments

50%

30%

15%

5%

10/22/2012 6 Copyright-Lean Quality Associates, all rights reserved

Wastes in Set-Up Defects

Overproduction

Waiting

Non-utilized

people

Transportation

Inventory

Motion excess

Extra processing

Typically 95% of Total Lead Time is Non-Value Added!!!

10/22/2012 7 Copyright-Lean Quality Associates, all rights reserved

Traditional setup Assumptions

Long runs are necessary

to amortize the cost of

setups

Managing production using

economic order quantities

(EOQ) balances setup costs

and inventory carrying costs

Inventory

10/22/2012 8 Copyright-Lean Quality Associates, all rights reserved

Traditional setup Math

Do these assumptions make sense if setup time

can be significantly reduced?

Fixed Cost

Variable

Cost

Lot/Batch Size EOQ

setup Cost

Inventory Carrying Cost

setup Cost + Inventory Carrying Cost

10/22/2012 9 Copyright-Lean Quality Associates, all rights reserved

Economic Order Quantity (EOQ)

xUnitCostyCostInventCarr

xOrderCosteAnnualUsagx

EOQ

(%)

/)(2

10/22/2012 10 Copyright-Lean Quality Associates, all rights reserved

Effect of SUTR on EOQ

0

200

400

600

800

1000

0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1

EOQ

EOQ

The effect of Setup Time Reduction on the

Computation of EOQ

10/22/2012 11 Copyright-Lean Quality Associates, all rights reserved

Set Up Improvement Process

A) Document the current setup

B) Analyze the setup and identify ways to reduce or eliminate it (SMED)

C) Implement improvements and monitor results

D) Standardize the improved setup

10/22/2012 12 Copyright-Lean Quality Associates, all rights reserved

The SMED System Step-by-step method to

reduce setup time

Developed by Shigeo

Shingo

Applicable in all

industries

Useful in streamlining

other processes

xchange of

S

M

E

D

ingle

inute

ie

setup in under 10 minutes 10/22/2012 13 Copyright-Lean Quality Associates, all rights reserved

Reducing setup Time

Put the “basics” in place

workplace organization

5 S’s

visual controls

Analyze and improve setup

using SMED

10/22/2012 14 Copyright-Lean Quality Associates, all rights reserved

SMED: Basic Principles

There are two types of setup tasks:

internal (machine down)

external (machine running)

Eliminating or streamlining a setup task

requires a clear understanding of that task’s

real purpose and function

Focus first on no/low cost solutions

The best setup is no setup!

10/22/2012 15 Copyright-Lean Quality Associates, all rights reserved

The Stages of SMED

• Document the current Setup process

• 1-Separate and convert internal elements to external

• 2-Streamline all aspects of setup

operations.

1

10/22/2012 16 Copyright-Lean Quality Associates, all rights reserved

Internal elements to External

Time

Before

Get

tools

Get

parts

Remove

parts

Add

parts Trial Processing

Get

tools

Get

parts

Preset

Parts

Remove

parts

Add

parts

Trial

Processing Internal

External After

10/22/2012 17 Copyright-Lean Quality Associates, all rights reserved

.

Parallel operations

Eliminating adj.

Functional clamps

Mechanization

Planning

Work place Layout

Team/Organize

Training

Pit-Crew Practice

Documentation

Streamline all elements

10/22/2012 18 Copyright-Lean Quality Associates, all rights reserved

Experience with SUTR

Cold Rolling Mill 62 min to 16 min

Grinding Op 35 min to 10 min

Press Brake 16:51 min to 7:08m

Vacuum Evaporator65 min to 22 min

10/22/2012 19 Copyright-Lean Quality Associates, all rights reserved

Additional questions?

Industrial Engr.

Lean & Lean Six Sigma

RABQSA-Principal Auditor

ISO-9000, TS-16949, 17025

(262)-834-8476

[email protected]

www.leanquality.net

10/22/2012 20 Copyright-Lean Quality Associates, all rights reserved