The Lean Enterprise Quick Change Over / Set-Up Reduction

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Lean Foundations

Continuous Improvement Training

• Understand the concepts and principles of Set-up Reduction.

• Share some ideas and understand the benefits of Set-up Reduction.

• Apply the concepts, principles and techniques of SMED to accomplish

Quick Changeovers !!

Objectives

? What is SMED?

SMED stands for:

Single Minute Exchange of Die

Ideally, set-up time should be

anything less than 10 minutes …

Decreased set-up time;

reduces the need for inventory,

provides more flexibility and capacity,

enables us to better serve our customer!

Set-up Time

There are two types of setup time:

Internal Set-up:

Those activities that must be performed while the

machine is shut down. (Work content done in

addition to Machine Time.)

Example: Removing dies and tooling

External Set-up:

Those activities that are performed while the

machine is operating.

Example: Preparing tooling for the next set-up

Set-up Reduction Process

1. Observe and document the current set-up.

2. Separate Internal and External elements.

3. Improve each element.

4. Observe and document the new set-up process.

5. Standardize the new set-up procedure.

6. Celebrate your success!!

Observe and Document the Current Set Up

A. Select a specific set-up for improvement

B. Identify a set-up “kaizen” team.

C. Observe the set-up process:

Video Record the set-up process

Complete the Set-up Operations Analysis

chart (before Kaizen).

D. Prepare a Pareto chart for each time category.

Record and Recommend

During this phase we:

Observe and document the existing set-up procedure

using

Time Observation and Video Recording techniques

- Analyze all work efforts

- Identify short-term solutions that can be

implemented with procedural changes, modifications to

existing fixtures and minor investment in tooling

Video Recording Tips

Collect background data

Select regular production “Parts”

Determine equipment and operation

Prepare/Evaluate site

Where does operator stand?

Where is the best position for the camera?

Is there adequate lighting?

Narrate

Describe what is happening when the

operator blocks the camera or leaves

the area.

Analyze the Time Observation & Video

Review Time Observation and Video

with the team

Identify opportunities

Internal vs. External

Value Added Vs Non-Value Added

Normal vs. Abnormal

Seven Types of Waste

Automatic, Manual, Walking,

and Waiting times

Solicit ideas for countermeasures /

improvements

Mach # 3456 Before Kaizen AnalysisMinutes From To Area / Department Date 3/7/99

146 Part # Model A Model B Machining Cell

Step No. Changeover Element Element Elapsed Internal External Waste Improvement Plan Eliminate

Internal to

External Reduce

1Pick-up tools from tool crib

(search)19 19 19 x Mount hand tools on machine x

2Remove Fixture (Fixture

Change)15 34 15

Air wrench at machine .

Eliminate bolts - install

quick release. Design SMED

cart to load fixture.

x

3 Look for Tools (Search) 5 39 5 x Mount hand tools on machine x

4Remove Fixture (Fixture

Change)7 46 7 See step 2. x

5Clean & prepare subplate

(Fixture Change)10 56 10 Steel plugs for subplate. x

6Prepare nex fixture (Fixture

Change)20 1'16 20 x

Standardize procedures to

externalize this step.x x

7Put on new fixture (Fixture

Change)22 1'38 22

Air wrench at machine .

Eliminate bolts - install

quick release. Design SMED

cart to load fixture.

x

8Remove preset tools (Tools

Change)4 1'42 4

Establish common tooling for

all models.x x

9 Preset tooling (Tool Change) 6 1'48 6Standardize procedures to

externalize this step.x

10Load new tooling (Tool

Change)11 1'59 11

Establish common tooling for

all models.x x

11 Run 1st Piece (1st Piece) 15 2'14 15

12 Qualify 1st Piece (Gage) 12 2'26 12Standardize procedures to

externalize this step.x

Totals2'26 2'26 2'11 15

Operation Time Changeover Categories Goal of Improvement Plan

Set-up Operations Analysis Chart

Observe and Document the Current Set Up

Observe and Document the Current Set-up Searching

- Looking for tools, jigs, fixtures, etc.

Fixture Change

- Replacing one fixture with another

Tool Change

- Replacing existing tooling

Programming

- Making adjustments or changes to a CNC program in order to

accommodate the new set-up

Walk time

- The time an operator must walk to retrieve a fixture, tools etc.

1st Piece

- The time required to produce a good unit after the initial set-up

Gage

- The time required to qualify the 1st piece

Set-up Pareto Analysis

0

10

20

30

40

50

60

70

80

tim

e in

min

Fixture Chg Search Tool Chg 1st Piece check Calibrate Gauge

Pareto Analysis on each Time Category

Separate the Elements Internal:

Those activities that must be performed while

the machine is shut down.

Example: Removing dies and tooling

External:

Those activities that are performed while the

machine is operating.

Example: Acquire fixture/tools for next set-up

Both types of actions must be separated. Once the machine is stopped, the associate should never

depart to perform any part of the external set up.

Mach # 3456 Before Kaizen AnalysisMinutes From To Area / Department Date 3/7/99

146 Part # Model A Model B Machining Cell

Step No. Changeover Element Element Elapsed Internal External Waste Improvement Plan Eliminate

Internal to

External Reduce

1Pick-up t ools from t ool crib

(search)19 19 19 x Mount hand t ools on machine x

2Remove Fixt ure (Fixt ure

Change)15 34 15

Air wrench at machine . Eliminat e bolt s -

ins t all quick release. Des ign SMED cart

t o load fixt ure.x

3 Look for Tools (Search) 5 39 5 x Mount hand t ools on machine x4

Remove Fixt ure (Fixt ure

Change)7 46 7 See s t ep 2. x

5Clean & prepare subplat e

(Fixt ure Change)10 56 10 St eel plugs for subplat e. x

6Prepare nex fixt ure (Fixt ure

Change)20 1'16 20 x St andardize procedures t o ext ernalize t his s t ep. x x

7Put on new fixt ure (Fixt ure

Change)22 1'38 22

Air wrench at machine . Eliminat e bolt s -

ins t all quick release. Des ign SMED cart

t o load fixt ure.x

8Remove preset t ools (Tools

Change)4 1'42 4 Est ablish common t ooling for all models . x x

9 Preset t ooling (Tool Change) 6 1'48 6St andardize procedures t o ext ernalize

t his s t ep. x10 Load new t ooling (Tool Change) 11 1'59 11 Est ablish common t ooling for all models . x x11 Run 1s t Piece (1s t Piece) 15 2'14 15

12 Qualify 1s t Piece (Gage) 12 2'26 12St andardize procedures t o ext ernalize

t his s t ep. x

Totals2'26 2'26 2'11 15

Operation Time Changeover Categories Goal of Improvement Plan

Set-up Operations Analysis Chart

Internal or External?

Separate the Elements

Develop Improvement Plan

5S +1 (6S) discipline is the key to quick changeover!

Every minute spent

looking for tools,

fixtures, drawings, dies,

jigs or other materials

adds to the set-up time.

A ‘strong’ 5S foundation, with a ‘point-of-use’ (POU)

methodology, will ensure that all required materials

are in place when needed, are clean, and in working

condition.

Develop Improvement Plan Remember the ‘Wastes’ ? (refer to the 7W’s)

Defects

Over-Production (inventory)

Transportation

Waiting

Inspection (mass)

Motion

Processing, itself

+ “Unused Creativity”

Storage area for Dies

Tool Cart

Punch Press

Tool Room

Develop Improvement Plan

Specifically:

A. Convert as much of the internal set

up to the external set up.

B. Eliminate or reduce the internal and

external set-up.

C. Eliminate the adjustment process.

Ultimate Goal: Eliminate Set-up!

Application Best Practices

1) Make minor modification to the

existing fixtures.

2) Implement Point-of-Use (POU) techniques.

3) Identify additional tooling to remove attachment

from internal to external.

4) Adopt standardized tooling.

5) Document time savings.

Application Best Practices - Continued

For example:

Slots in fixture and T-Bolts reduce

attachment time.

A new part holder reduced the time required to

load and unload parts to fixture. Swing hook

eliminated the need to remove nut from bolt.

Extra set slides allow detach to be completed on

external time.

Other ideas

1. Quick Changeover begins and ends with the 5S’s.

2. Change the Internal set-up into External, then improve

the remaining Internal set-up time.

3. Bolts are our Enemies.

4. If you have to use your hands make sure your feet stay

put.

5. Don’t rely on Special Fine-tuning skills.

6. Standards are standard: they are NOT flexible.

7. Standardize all SMED Operations

Document the New Set-up

A. List each element on the Set-up

Operations Standard Chart (after Kaizen)

B. Video tape the new set-up procedure.

C. Record the set-up time for each element

D. Note areas for future improvement.

Mach # After KaizenMinutes From To Area / Department Date

Part #

Step No. Changeover Element Element Elapsed Internal External Waste Comments / Future Improvement Plans

Operation Time Changeover Categories

Set-up Operations Standard

Standardize the New Procedure

Standardize the New Procedure

The Set-up Operations Standard chart will

become the basis for the new set-up

procedure.

Prepare the appropriate detail and work

instructions that will be included on the Set-

up Operations Standard chart.

Assure that all appropriate personnel are

trained in the new procedure.

The Lean Enterprise Quick Change Over / Set-Up Reduction

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Lean Foundations

Continuous Improvement Training