1 Setup Reduction For CNC Principles Copyright 2001

2 Setup reduction principles: J Definition of setup time J Two task types related to setup J Three ways to reduce setup time J Four steps to setup reduction

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4 Definition of setup time: The time it takes to go from making the last workpiece in the most recent production run…

5 Definition of setup time: 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!

6 By our definition: Definition of setup time: If you’re running but one workpiece… …there is no production run If you have machines dedicated to one job… …there is no setup

7 Much is directly related to setup: 4Tear down old setup & put everything away 4Clean machine 4Make new setup 4Cutting tool tasks 4Assemble, measure, and enter offsets for 4Assign program zero 4Measure position and enter fixture offsets 4Load program 4Verify program 4Optimize program

8 But maybe some non-productive activities: 4Time spent gathering needed items 4Hand tools 4Cutting tools 4Fixtures 4Gauges 4Material 4Paperwork 4Storage containers ?

9 Or maybe some non-productive activities: 4Time spent gathering needed items 4Personal time 4Breaks 4Lunch 4Phone calls

10 Or maybe some non-productive activities: 4Time spent gathering needed items 4Personal time 4Time spent waiting 4For inspection 4For tool crib attendant 4For fork lift operator These are all fair game for your setup reduction program!

11 4Tear down old setup & put everything away 4Clean machine 4Make new setup 4Cutting tool tasks 4Assemble, measure, and enter offsets for 4Assign program zero 4Measure position and enter fixture offsets 4Load program 4Verify program 4Optimize program Core tasks: 4Time spent gathering needed items 4Personal time 4Time spent waiting 4For inspection 4For tool crib attendant 4For 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!

12 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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14 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!

15 Two setup-related task types: 4Tear down old setup & put everything away 4Clean machine 4Make new setup 4Cutting tool tasks 4Assemble, measure, and enter offsets for 4Assign program zero 4Measure position and enter fixture offsets 4Load program 4Verify program 4Optimize program 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

16 4Programming 4Cutting tool assembly 4Gathering of hand tools 4Gathering of fixtures 4Gathering of gauges Tasks commonly done off line Two setup-related task types: The more people in the CNC environment, the more that can be done off line

17 Two setup-related task types: Important points: The machine is down during the performing of on-line tasks The machine is running during the performing of off-line tasks

18 Two setup-related task types: 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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20 Three ways to reduce setup time: Eliminate (especially on-line) tasks You save the amount of time it was taking to perform the task

21 Three ways to reduce setup time: Eliminate (especially on-line) tasks You save the amount of time it was taking to perform the task Eliminate the task Remember, 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!

22 Three ways to reduce setup time: Eliminate (especially on-line) tasks You save the amount of time it was taking to perform the task Move on-line tasks off line At least the machine is not down during the performance of the task

23 Three ways to reduce setup time: Eliminate (especially on-line) tasks You save the amount of time it was taking to perform the task Move on-line tasks off line At least the machine is not down during the performance of the task 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

24 Three ways to reduce setup time: Eliminate (especially on-line) tasks You save the amount of time it was taking to perform the task Move on-line tasks off line At least the machine is not down during the performance of the task Facilitate tasks Make it as quick & easy as possible to perform the task

25 Three ways to reduce setup time: Eliminate (especially on-line) tasks You save the amount of time it was taking to perform the task Move on-line tasks off line At least the machine is not down during the performance of the task Facilitate tasks Make it as quick & easy as possible to perform the task 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

26 Three ways to reduce setup time: Eliminate (especially on-line) tasks You save the amount of time it was taking to perform the task Move on-line tasks off line At least the machine is not down during the performance of the task Facilitate tasks Make it as quick & easy as possible to perform the task All setup reduction techniques fall into one of these three categories!

27 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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29 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 methods 2)Brainstorm for improvements 3)Assign and implement changes 4)Gauge success Planning form is in your manual

30 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

31 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 time Before you attempt to improve a setup task, you must know how long the task is currently taking! Step one: Evaluate current methods

32 Step one: Evaluate current methods 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

33 4Get everyone’s approval 4Watch for unusual behavior 4Use a camera with time/date The best way is to video tape the task… Step one: Evaluate current methods You must be able to gauge the impact of any change on your CNC environment!

34 …another way is to simply time the task Step one: Evaluate current methods You must be able to gauge the impact of any change on your CNC environment! But it will be much more difficult to evaluate complexity

35 Step one: Evaluate current methods You must be able to gauge the impact of any change on your CNC environment!

36 What you may find: A high degree of disorganization! Your greatest initial improvement may be… …to get better organized KOrganization of hand tools KOrganization of cutting tools KOrganization of fixtures KCleanliness of work area KMisplaced items KPoor documentation KMinimal engineering support KConflicting methods KNo communication KTooling not available

37 Setup reduction form: