Quick Set-Up Technique GO DONE READY External Internal 0 SEC 10 SEC 14 SEC GAS H2O

LEAN MANUFACTURING Concept of Reducing Cost by Identifying and Eliminating Waste Throughout the Manufacturing Process Time Lost Changing Over a Process Is a Form of Waste. Quick Set-up Techniques and the Related Tools Used During This Workshop Identify Wastes in a Set-up and Generate Solutions to Eliminate Those Wastes

Race The Journey to World Class CURRENT SET-UP TIME Gap WORLD CLASS The Quick Set-Up Tool Provides the Means to Move Closer to World Class and Close the Gap Gap WORLD CLASS (TEN MINUTES or LESS)

WHAT IS THE EFFECT OF “SLOW CHANGEOVERS”?? Inventory More than is needed Lead Time Longer than necessary Quality Not as good as it could be Cost Higher than Competitors Capacity Lower than it could be New Business May not be able to capture

QUICK SET-UP TECHNIQUE Focuses on Capacity Improvements by Reducing “Set-up” or Changeover Time of a Process/Activity Two/Three Day Workshop Conducted at the Work Site Focusing on a Specific Set-up/Changeover Workshop Includes Some Training of Quick Set-up Concepts and Creativity to Rid Set-up of Waste

QUICK SET-UP TECHNIQUE Characteristics Focus is on Improving Equipment Up-Time (rather than labor efficiency) Utilizes People to Their Fullest Capacity (which requires Cooperation, Training & Understanding) Requires Constant Change (Continuous Improvement) Goal is to run every Part Number every day

QUICK SET-UP TECHNIQUE GOAL: Decrease Set-up Time by 50% (Short Term Goal) Single Digit Set-up Times (Long Term Goal) Get Equipment Running Good Parts ASAP Changeover Equipment More Frequently Run Smaller Lot Sizes

QUICK SET-UP TECHNIQUE Process Steps: 1. Measure Current Set-Up Times 2. Form Set-Up Reduction Team 3. Analyze Current Set-Up Method 4. Convert “Internal” Elements to “External” 5. Simplify Remaining “Internal” Elements 6. Simplify “External” Elements 7. Minimize “1st Piece” Qualification Time 8. Identify and Train Set-Up Crew 9. Apply Continuous Improvement 10. Capitalize on Set-Up Improvement

QUICK SET-UP TECHNIQUE TYPICAL AGENDA

QUICK SET-UP TECHNIQUE Benefits Reduced Lot Sizes Reduced Inventories Improved Quality Increased Capacity/Uptime Improved Responsiveness Reduced Floor Space Required Operator Productivity Improved

QUICK SET-UP TECHNIQUE Sample of Results ORIGINAL IMMEDIATE SHORT TERM SUPPLIER TIME IMPROVEMENT IMPROVEMENT Supplier E 194 min. 107 min. (45%) 74 min. (62%) (Fasteners) Supplier E 390 min. 101 min. (74%) 60 min. (85%) (Injection Molding) Supplier G 170 min. 60 min. (65%) 45 min. (74%) (Stampings) Supplier M 72 min. 29.5 min. (65%) 29.5 min. (65%) Supplier D 156 min. 46.5 min. (70%) 30 min. (81%) Supplier S 75 min. 50 min. (33%) 28 min. (63%)

QUICK SET-UP TECHNIQUE THE GOAL

PRE-TRAINING ACTIVITIES Select Changeover to Be Studied Select Team Members Inform Team Members of Workshop What Is It When Will It Be Why Was I Selected Video Tape Current Set-up Prior to Workshop Send Copy of Tape Prior to Workshop

PRE-TRAINING ACTIVITIES SELECT PROJECT Longest Set-Up Time High Probability of Success Bottle Neck Operation Large Current Run Size

SUGGESTED TEAM MAKE-UP PRE-TRAINING ACTIVITIES SUGGESTED TEAM MAKE-UP Persons Doing Set-up Set-up Reduction Facilitator Related Skilled Trades Area Supervisor Related Tool Engineer Related Manufacturing Engineer Outside Resources, i.e. Machine or Tool or Mat’l Supplier 4-8 PEOPLE TOTAL

PRE-TRAINING ACTIVITIES (CONTINUED) VIDEO TAPE CURRENT SET-UP (Gather Data) - Start @ Last Good Piece of Prior Part Number - Tape “What’s Happening” at the Process (Don’t Follow Set-up Operators) - End Taping When First Good Piece of New Part Number Is Accepted - Include All “Normal Delays” in Study - Record “Clock Time” on Tape

OTHER TRAINING NEEDS Meeting Room - Seating for 10 VHS Player and Monitor Overhead Projector and Screen Chart Paper/Stand Tablets for Participants Clipboards Lunch for Team Members During Workshop