Setup Reduction -- Creating More Production Time Dr. Richard A Setup Reduction -- Creating More Production Time Dr. Richard A. Wysk rwysk@psu.edu http://www.engr.psu.edu/cim March 20, 2003 11/28/2018

Make it better! Make it faster! Make it cheaper! Let’s spend a few minutes and talk about how we might make things: better, faster and/or cheaper. 11/28/2018

VOLUME VARIETY HIGH FLEXIBILITY TRANSFER PRODUCTION CAPACITY LINE SPECIAL SYSTEM FLEXIBLE MANUFACTURING SYSTEM VOLUME MANUFACTURING Cells STD. AND GEN. MACHINERY LOW HIGH VARIETY 11/28/2018

Readings Singo Shingeo, A Revolution in Manufacturing-The SMED-Single Minute Exchange of Dies-System, Productivity Press, 1981. Chapter 18 of Computer Aided Manufacturing, Wang, H.P., Chang, T.C. and Wysk, R. A., 3rd Edition (2004 expected) http://www.engr.psu.edu/cim/active/ie450ho1.pdf 11/28/2018

Objectives To be able to identify internal and external process elements To be able to apply methods improvements techniques to manufacturing To calculate/measure the various Production Time Elements To be able to apply the techniques of set-up reduction 11/28/2018

Exercise Readiness Assessment Test A.K.A. RAT Complete the RAT for this module before you meet to discuss this for class. What set up reduction activities did you select as having value added to you for personal benefit? 11/28/2018

How long does it take to produce something? It is not unusual for the processing time to be a very small part of the time required to make a component. Order materials Accumulate parts Setup machine 11/28/2018

JIT -- Speed is everything! Some Just in time models Buying bread Buying milk Buying “take-out” 11/28/2018

Exercise What are the most important factors that contribute to the production time (average time required to produce a single unit/product)? 11/28/2018

Between .05% and 5% of the time Value is being added to a product In Industry Between .05% and 5% of the time Value is being added to a product 11/28/2018

What are the Value added activities at PSU Inc.? Receiving -> Material handling -> Machining -> Assembling -> Packaging 11/28/2018

Are we really adding value What percent of the time are the machines producing good product? What percent of the time are the moving and setting up? 11/28/2018

Producing a product Production time (per lot) = setup time (per lot) + manufacturing time (per lot) 11/28/2018

Producing a product Manufacturing time (per piece) = material handling and locating time (per piece) + manufacturing time (per piece) 11/28/2018

Product time (per piece) Total production time = S (set up time + load/unload time + processing time + idle time + tool change time) + initial set up time L/UL m c = S(t j setup + t i + t )/ Nb + tset / Nt t P A 11/28/2018

= S(t + t + t )/ Nb + tset / Nt t t L/UL m c = S(t j setup + t i + t )/ Nb + tset / Nt t P A t j setup m c i set the time required for setup for an operation (load fixture, retrieve tooling , etc.) the time required to load and unload a product for feature operation j (chuck, fixture, etc..) the machining/processing time for feature j tool change time/part idle time due to scheduling control the time required for initial setup, e.g., fixture design, process planning, etc.) L/UL 11/28/2018

t = + Production time per piece set l/ul m Ch / N b = + The cost associated with new tooling is also a key consideration for the designer. For low and medium volume products, the cost associated with tooling and setup can dominate the total product cost. 11/28/2018

The product cost can be expressed as: Production cost per piece, Cp C p mo t p/t setup bt = t + / n 11/28/2018

Cmo is the cost of machine and operator/hour where Cmo is the cost of machine and operator/hour Ct is the perishable tooling cost np/t is the number of pieces that can be produced per tool Csetup is the setup resource cost for the part (fixture, jig, steady-rest, etc) nbt is the total number of parts to be produced 11/28/2018

Simple CNC Example New batch of parts arrives Run parts Change over tools for the batch Set offsets for new tools Load NC program Validate Run parts Load part onto machine Cycle start and wait Unload and visually inspect (adjust if necessary) Setup time per lot Material handling and loading time per piece 11/28/2018

Graphically it looks like TOTAL TIME TO PRODUCE A LOT OF PRODUCT SETTING UP THE MACHINE RUNNING THE MACHINE AND OFF-LINE MEASUREMENT This can be > 30% of the TOTAL TIME TO PRODUCE A LOT 11/28/2018

A look at SETUP SETTING UP THE MACHINE This can be > 30% of the TOTAL TIME TO PRODUCE A LOT Setup consists of activities that must be performed on the machine (these are called Internal Elements), and elements that can be performed off-line or while the machine is producing a product (these are called External Elements) 11/28/2018

Rapid Tool Change-over Setup consists of Internal Elements - Elements that must be performed on the machine itself External Elements - Elements that can be performed “off-line” 11/28/2018

A look at SETUP (cont’d) SETTING UP THE MACHINE Internal Elements External Elements These External Elements can be completed while the machine is producing good product. For instance, we can clean a die set after the machine comes up. We can preassemble components for a setup. 11/28/2018

A look at SETUP (cont’d) SETTING UP THE MACHINE Internal Elements External Elements RUNNING THE MACHINE If the External Elements are performed while the machine is producing good parts then we can reduce the TOTAL PRODUCTION TIME by starting production earlier. 11/28/2018

Premise for SMED Idle time waiting for materials or other resources Set up time where machine is down while operators prepares for next activity Processing time - adding value to raw materials 11/28/2018

Graphically it looks like TOTAL TIME TO PRODUCE A LOT OF PRODUCT SAVINGS SETTING UP THE MACHINE RUNNING THE MACHINE AND OFF-LINE MEASUREMENT Production Time gained 11/28/2018

Premise for SMED Methods improvements Idle time waiting for materials or other resources Set up time where machine is down while operators prepares for next activity Processing time - adding value to raw materials 11/28/2018

Exercise (5 minutes) As an individual, describe a process that you know well (from work, food preparation, office activities…) Identify the internal and external elements for setup or work changeover. 11/28/2018

Methods Improvement Standard ways to improve setup efficiency Power tools Collets and quick-change fixtures 2nd set of fixtures and tools Setup layout Setup accumulation 11/28/2018

Examples of Improved Methods 11/28/2018

Make the tool part of the screw device -- you don’t need a tool, and this will save time in disassembling and reassembling the tooling and fixturing! 11/28/2018

Reduce the amount of turns required in order to activate the screw. 11/28/2018

Reduce the amount of screw turns and eliminate the tool! 11/28/2018

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Areas with potential benefit Screws and screw fasteners Tedious manual activities Power tools can be appropriate Connectors Others???? 11/28/2018

Currently changeover is done with these tools 11/28/2018

Currently changeover is done with these tools 11/28/2018

How about power tooling? 11/28/2018

How about cordless power tooling? 11/28/2018

Exercise As an individual, describe what methods, improvements, you could make to the setup/change over activity for the Case production system or some other system that you are familiar with? 11/28/2018

SMED is employee driven Train Area supervisors and operators Some implementation with outside consultant Most implementation within your company 11/28/2018

Questions? 11/28/2018