AnalyzeAnalyze ImproveImproveDefineDefine MeasureMeasure ControlControl

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rove

Imp

rove

LEANSIX SIGMA

LEANSIX SIGMA

Ensuring Value(Part 2)

Quick Changeover / Set-up Reduction

AnalyzeAnalyze ImproveImproveDefineDefine MeasureMeasure ControlControl

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Imp

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LEANSIX SIGMA

LEANSIX SIGMA

Set-Up Reduction Set-Up Reduction Introduction

Effect of Set-Up Reduction

The Four-Step Method

Implementing Set-Up Improvements

RD010402

Module 13 3

Improve

Total Cost is Key (review) In Lean Manufacturing, we focus on reducing waste

in our processes, by focusing on: Productivity (pieces per hour; cycle time; schedule

attainment) Quality (scrap and rework; fit with customer needs) Downtime (equipment uptime; availability of qualified

personnel) Speed (on-time delivery; lead-time; order-to-delivery) Cost (to produce each piece; overtime; expediting)

The Seven Deadly Wastes• Over-producing• Waiting• Over-processing• (Too Much) Inventory• (Unnecessary) Motion• Defects or Rework• (Excessive) Transportation and Materials Handling• Plus One More: Underutilized (Human) Resources

Module 13 4

Improve

Cycle Time Barriers (review)

Set-up Events are one of the key barriers to fast cycle times.

Input Output

Cycle Time

Operation 1

Operation 2

Operation 3

Operation 4

Multi-Step Process

Module 13 5

Improve

Production

Downtime Ramp-up time

Job# 1

Job# 2

What Is Set-Up Reduction?Set-Up Reduction is a process in which the time and

effort for equipment changeover is reduced to an absolute minimum without adversely affecting quality.

Two components of set-up reduction that must be addressed are: Machine down time or set-up/changeover time Machine ramp-up time (i.e., making adjustments to meet

specs)Total Time Lost to S/U and

C/O

Module 13 6

Improve

Set-Up Time Defined

50%

30%

5%

15%

Last GoodProduct of Run

First GoodProduct(s) of Run

Preparation

Trial Runs

Adjustments

Actual S/U

A B

Set-Up Time is the length of time between the last good product of a production run to the first good product(s) of the next

production run

Set-Up Time

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Components in the Set-Up Process Preparation:

Obtain work order and instructions

Gather and return tools

Retrieve and return change parts

Clean machine Check materials Clean work areas

Set-Up: Change machine /

equipment hardware Mount and remove

dies, tools, blades, etc.

Adjustments: Measure / calibrate Center dies, tools,

blades, etc. Modify settings

Trial Runs: Adjust after test or 1st

piece product is made Inspect / measure test

piece or 1st piece

Module 13 8

ImproveAdvantages of Rapid Set-Up Over Typical Set-Up

Cut scrap and rework risk by 50+%

Cut inventory investment by 50+%

Able to introduce quality improvements at twice the rate (more cycles of learning)

Able to change the schedule twice as often to meet changing customer demands

Able to introduce design changes at twice the rate

Increase available floor space

,

,

Module 13 9

Improve

Four-Step Set-Up Reduction Method 1. Document Set-Up and then Separate Events into

Internal and External

2. Convert Internal Events to External Events

3. Streamline Internal Set-Up

4. Eliminate Adjustments

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Step 1 of 4

STEP 1Document the set-up and

separate events into internal or external

STEP 3Streamline internal

events(Simplify, Reduce,

Eliminate)

STEP 2Convert Internal

to External events

STEP 4Eliminate

adjustments internal to the set-

up

Step 1 is done first to attain benefits quickly

D, MD, M

A, IA, I II I, CI, C

xxxx“Corresponding” DMAIC phase for a stand-alone Set-Up Reduction project

Module 13 11

ImproveStep 1: Goal of Step 1

Goal: Document the set-up and separate into internal and external events: Internal Set-Up is an event that must be performed while

the equipment is down (not running or producing parts). Exchanging dies/fixtures in the machine

External Set-Up is an event that may be performed while the equipment is producing parts. Retrieving drawings, tools, hardware and parts Loading programs

Module 13 12

Improve

Physical Flow (review) Physical Flow represents the path of movement a

product family follows through a facility. The flow of the material (or a worker) is traced though the facility’s layout, showing the path and distance traveled while completing a task.Effects of Poor Physical Flow

• Long process cycle times• Excess materials handling or wait times• Damage to goods in-transit• Increased chance for injuries• Poor visibility to actual production

Typical Causes of Poor Physical Flow• Lack of materials handling equipment• Long distances between work stations• Large loads, batches or transfer sizes• Un-ergonomic placement of equipment• Poor process design or task order

Module 13 13

ImproveStep 1A: Area Layout Diagram (a.k.a. Spaghetti Diagram)

Document relative position of cabinets, tools, dies/fixtures, hardware, etc., in relation to the set-up activities

Record the movements of the operators/set-up personnel throughout the set-up activities

Track each foot traffic movement of key operators/set-up personnel to determine the total distance traveled during the operation Key in gaining buy-in (especially from the operators) to the

improvement suggestions

Module 13 14

ImproveStep 1A:Creating and Using the Area Layout

PunchPress#1465

Tool Carousel

Controls

Tool/Die & Fixture Room

Hardware Cage

ProductionControl

QualityControl

Hand ToolCabinet

Note: To enhance area layout readability, consider numbering each traffic line and / or use multiple area layout pages

Module 13 15

ImproveStep 1A:Area Layout (Example)

Does this appear efficient?

This set-up could probably be streamlined with better storage and location of needed items!

Module 13 16

ImproveStep 1A & 1B:Set-Up Documentation Worksheet

ITEM # _____________________________

See copy in Excel format within Appendix A

Module 13 17

Improve

Step 2 of 4

STEP 1Document the set-up and

separate events into internal or external

STEP 3Streamline internal

events(Simplify, Reduce,

Eliminate)

STEP 2Convert Internal

to External events

STEP 4Eliminate

adjustments internal to the set-

up

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Goal: Convert internal set-up events to external events: Re-examine internal events from Step 1 and verify they

are actually internal Convert any internal set-up events to external set-up

events using focused, engineered methods Change set-up procedures to reflect only internal activities Develop external activity procedures Use Brainstorming tools abundantly to gather and build

good ideas

Step 2: Goal of Step 2

Module 13 19

ImproveStep 2: Improvements Worksheet

The Improvements Worksheet is used to document all improvements to the set-up.

The worksheet is used to develop action plans (Continuous Improvement ‘To-Do’ List) and work orders that will initiate improvement implementation.

The reduction in set-up time is calculated on this sheet as improvements are implemented over time.

Module 13 20

ImproveStep 2: Improvements Worksheet (Example)

See copy in Excel format within Appendix A

Module 13 21

ImproveStep 2:Organize for Set-Up

Fact: Vast amounts of set-up time are lost due to searching for set-up hardware and set-up information. Set-Up Hardware:

Tools Fixtures Nuts and Bolts Clamping Devices Measuring Devices

Set-Up Information: Data (Tool and Machine Settings) Procedures Drawings

Module 13 22

ImproveStep 2:Organizing Set-Up Hardware

Set-Up hardware should be organized by either specific set-ups or by specific hardware or workstation.

Set hardware should be stored near the workstation. The storage locations should be labeled as to what set-

up or component is stored at that location. The fixtures and tools should be organized to easily

determine if components are missing prior to set-up (shadow-boards).

Set-Up data for machine settings, tooling settings and shim sizes should be placed on designated charts and stored near the workstation.

Detailed set-up procedures should be stored near the workstation.

Module 13 23

Improve

Time Action Parts89 Setup A101112 Setup B13

Part #432543Press # P-10 Review Check TableDie 274 Functional ChecksDie Location Shelf 4 Retrieve Change Parts

CRESCENTWRENCH

SCREWDRIVER

ALLENWRENCH

Step 2:Applications of Step 2

Checklists

Check Tables or Shadow-boards

Battle Plans

Functional Checks

Improving Transportation

Module 13 24

ImproveStep 2:Checklists

Checklist of parts and steps required in set-up Names of Tools Specifications Identification of Change

Parts (nozzles, pipes, hoses, etc.)

Settings (temperature, pressure, location, etc.)

Numeric Values for Measurements

2mm 4mm 5mm 6mm 14mm3/32 3/16 1/4 5/1624mm 27mm1 1-3/16 1-9/16 Adjustable wrenchChannel Lock Loc-Line Needle Nose

T-6 T-8

Large and Small

Part Description

Setup Tool List

Wrenches

Torx Wrenches

Cheater Bar

Soft face Hammer

Pliers

Ratchet with 14mm allen wrench

Flat head screwdriver

Part No.

Common Tools

Shim for workshift

Allen Wrench

Tap/Drill

Boring Bar

4 Flute End Mill

2 Flute End Mill

Specific Tools

File

Collet

Bore micrometer

O. D. micrometer

Thru Bore ref. gage

Key Way Go/No go

Bore Go/No go

Spade Drill & insert

Carbide Drill

Module 13 25

ImproveStep 2:Checklist (Example)

Press #: P-10

Die #: 274

Die Location: Shelf 4

Platen #: 42

Platen Location: Shelf 5

Tools: Die Cart, 1/4” and 1/8” Allen Wrench, Screwdriver, 1/4” Open-Ended Wrench

Settings: Ram 12.50

External Events Review check table Retrieve change parts Tools clean and in working

order Change parts clean and in

working order Functional checks completed

Part #: 432543

Module 13 26

ImproveStep 2:Check Table or Shadow-Boards

Provides "quick check" for tools. Tools are placed over drawings or outlines drawn on check

table or shadow-board. Missing tools are easily identified. Tools should be retrieved during external set-up time.

CRESCENTWRENCH

SCREWDRIVER

ALLENWRENCH

Module 13 27

ImproveStep 2:Battle Plans

Developed daily

Everyone involved in set-up and operation must know battle plan

TIME ACTION PARTS NOTES 8:00 AM 8:30 AM SETUP 031476 TEAM 1

9:00 AM 9:30 AM

10:00 AM SETUP 413222 TEAM 1 10:30 AM 11:00 AM 11:30 AM 12:00 PM 12:30 PM 1:00 PM 1:30 PM 2:00 PM 2:30 PM 3:00 PM 3:30 PM 4:00 PM SETUP 192413 TEAM 2 4:30 PM 5:00 PM

Module 13 28

ImproveStep 2:Functional Checks/Improving Transportation

Functional Checks Used in conjunction with checklist and check table

to determine if all set-up parts, tools, etc. are in perfect working order

Must be performed externally

Improving Transportation of Change Parts All transportation of change parts must be

performed externally Make use of a set-up tool cart, pail, tray or belt

Module 13 29

ImproveStep 2:Die Retrieval for Punch Press

OLD - 35 min

Continue set-up

Stop press - begin internal set-up

Remove die from press

Transport die to storage area

Retrieve new die from storage area

Transport die to press

Place die on press

35 m

in

Replace old die to storage

Retrieve new die from storage area

Continue set-up

Replace new die on press

Remove die from press

Stop press - begin internal set-up

Exte

rnal 11 m

in

NEW - 11 min

External events for the next run are to be performed while the prior part is being run.

Module 13 30

Improve

Step 3 of 4

STEP 1Document the set-up and

separate events into internal or external

STEP 3Streamline internal

events(Simplify, Reduce,

Eliminate)

STEP 2Convert Internal

to External events

STEP 4Eliminate

adjustments internal to the set-

up

Module 13 31

Improve

Goals of Step 3 Goal: Streamline internal set-up by streamlining

the internal set-up steps by:

Simplifying Movement

Reducing Movement

Eliminating Movement

Module 13 32

ImproveStep 3:Applications to Streamline Internal Set-Up

Reduce / eliminate need for hand tools

Reduce / eliminate nuts and bolts, hex nuts, etc.

Replace with quick fastening / releasing devices:

Single-motion securing

U-slot method

Pear-shaped hole method

Module 13 33

ImproveStep 3: Securing Method Exercise

Before: Traditional Securing Method 4 bolts per die 12 turns per bolt to secure

4 bolts/die x 12 turns/bolt = 48 turns/die 0.05 min/turn x 48 turns/die = 2.4 min/die 2.4 minutes to remove + 2.4 minutes to secure

4.8 minutes

4.8 minutes

Bolt with 12 Threads

Module 13 34

ImproveStep 3: Securing a Die, Pear Shaped Hole Method

After: Pear-Shaped Hole 4 bolts per die 1 turn per bolt to secure 1 turn per bolt to remove

4 bolts/die x 1 turn/bolt = 4 turns/die 0.05 min/turn x 4 turns/die = 0.2 min/die 0.2 min to remove + 0.2 min to secure

0.4 minutes0.4 minutes

Bolt with 12 Threads BUT only one turn to secure!

Module 13 35

ImproveStep 3:Securing a Die Comparison

Traditional = 4.8 Minutes

Pear-Shaped Hole = 0.4 Minutes

Internal Set-Up Time: Streamlined by 4.4 minutes Reduced by 92%

Internal Set-Up Time: Streamlined by 4.4 minutes Reduced by 92%

Module 13 36

ImproveStep 3:Nut & Bolt Improvement Methods

Reduce NumberReduce Numberof Screwsof Screws

U-Slot MethodU-Slot Method

ClampsClamps

Snap MethodSnap Method MagnetsMagnets

Pear Shaped Pear Shaped Hole MethodHole Method

Single Motion Single Motion ConnectionsConnections Use of CamsUse of Cams Toggle ClampsToggle Clamps

One-Turn One-Turn MethodMethod

Use Only 1 Type/ Use Only 1 Type/ Size of FastenerSize of Fastener

Module 13 37

ImproveStep 3:One-Turn Procedures

Eliminate lost nuts, bolts, different-size nuts and bolts

8 bolts to be removed 0 bolts removed8 half-turns to loosen

NEW – 1.6 min

OLD – 18 min

Module 13 38

Improve

Step 4 of 4

STEP 1Document the set-up and

separate events into internal or external

STEP 3Streamline internal

events(Simplify, Reduce,

Eliminate)

STEP 2Convert Internal

to External events

STEP 4Eliminate

adjustments internal to the set-

up

Module 13 39

ImproveStep 4:Goal of Step 4

Goal: Eliminating Adjustments The elimination of adjustments and trial runs by turning

intuition and guessing into fact and settings. Elimination means elimination – not reduction – in the

time required to perform adjustments.

Module 13 40

ImproveStep 4:Test Runs Are Typically 50% of Set-Up Time

Test Runs 50%

Test Runs 50%

Preparation30%

Preparation30%

Set-Up5%

Set-Up5%

Measurementsand Settings

15%

Measurementsand Settings

15%

Module 13 41

ImproveStep 4: Adjustments and Test Runs

Adjustments and test runs are normally due to: Inaccurate Centering Inaccurate Settings Inaccurate Dimensioning Inaccurate or Inadequate Measuring Poor Documentation

Module 13 42

ImproveStep 4: Eliminating Adjustments

Abandon reliance on intuition for settings

Settings as a result of intuition are inexact, are rarely replicable, and do not provide the required precision as constant value settings

Convert intuition to FACT

As long as settings are made based on intuition, there is no way to avoid adjustments and test runs

Module 13 43

ImproveStep 4: Pin and Place Method on Conveyor Rails

Before After

34 Minutes 8 Minutes

Screws

Slide & AdjustSlide & Adjust SetRail Fixed

Pins

One fixed side plus pre-determined settings on the other

side

Completely variable placement on both sides

Module 13 44

ImproveStep 4: Pin & Place Method Conveyor Rails Results

34 m

in8 m

in

NEW - 8 min

Pull securing pins

Move rail to appropriately marked width

Replace pin

Start production

OLD - 34 min

Loosen screws with 1/4” wrench

Slide rails into place using a bottle as the guide

Tighten screws with 1/4” wrench

Start production

Bottle jam

Continue production

Yes

No

Module 13 45

ImproveStep 4: Centering Method

Fixture

Machine Center

Adjustments

Machine Base

Fixture

Machine Base Centering BallOr Notch

Machine Center

Before After

Module 13 46

ImproveStep 4: Centering Method Results

Load & cut part

Correctdimensions

Make adjustments

Start production

Place fixture onto base

Take measurements

8 m

in

Before

Start production

Place fixture onto base centering using

centering ball

1 m

in

After

Average 2 Scrapped Parts

0 Scrapped Parts

Module 13 47

ImproveStep 4: Cap Sealer Height Setting

CONVEYOR

SEALER

Set Screw

SETTING

No indication of settings for specific bottle sizes

10 minute procedure with average 2 to 5 adjustmentsUp to 5 Bottles Scrap!

Indication and slots for each bottle size

CONVEYOR

SEALER

Pin

SETTING

50 cc

100 cc

150 cc

30 second procedure with zero adjustments

0 Bottles Scrap!

Module 13 48

ImproveStep 4: Machining Setting Checklist

Provide vehicle for converting settings based on intuition to settings based on fact!

PART # BASE SETTING FIXTURE

327-01 10 2B

493 8 2C

1141 6 1.1A

PI482.3 11 3A

Milling Machine M-25 Setting Checklist