1. Setup Reduction -- Creating More Production Time Dr. Richard A
Setup Reduction -- Creating More Production Time Dr. Richard A. Wysk March 20, 2003
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2. 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.
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3. VOLUME VARIETY HIGH FLEXIBILITY TRANSFER PRODUCTION CAPACITY LINE
SPECIAL
SYSTEM
FLEXIBLE
MANUFACTURING
SYSTEM
VOLUME
MANUFACTURING
Cells
STD. AND GEN.
MACHINERY
LOW
HIGH
VARIETY
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4. 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)
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5. 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
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6. 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?
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7. 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
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8. JIT -- Speed is everything!
Some Just in time models
Buying bread
Buying milk
Buying “take-out”
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9. Exercise
What are the most important factors that contribute to the production time (average time required to produce a single unit/product)?
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10. 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
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11. What are the Value added activities at PSU Inc.?
Receiving ->
Material handling ->
Machining ->
Assembling ->
Packaging
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12. 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?
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13. Producing a product Production time (per lot) =
setup time (per lot) + manufacturing time (per lot)
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14. Producing a product Manufacturing time (per piece) =
material handling and locating time (per piece) + manufacturing time (per piece)
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15. 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
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16. = 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
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17. 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.
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18. The product cost can be expressed as:
Production cost per piece, Cp C p mo t
p/t
setup bt
= t + / n
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19. 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
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20. 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
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21. 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
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22. 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)
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23. 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”
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24. 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.
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25. 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.
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26. 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
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27. 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
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28. 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
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29. 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.
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30. 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
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31. Examples of Improved Methods
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32. 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!
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33. Reduce the amount of turns required in order to activate the screw.
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34. Reduce the amount of screw turns and eliminate the tool!
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38. Areas with potential benefit
Screws and screw fasteners
Tedious manual activities
Power tools can be appropriate
Connectors
Others????
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39. Currently changeover is done with these tools
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40. Currently changeover is done with these tools
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41. How about power tooling?
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42. How about cordless power tooling?
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43. 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?
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44. SMED is employee driven
Train Area supervisors and operators
Some implementation with outside consultant
Most implementation within your company
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45. Questions?
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