set-up reduction - sc21...set up reduction definition a concentrated and structured approach to the...
TRANSCRIPT
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Set-up Reduction
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Set Up Reduction
Definition
A concentrated and structured approach to the reduction or elimination
of all activities that take place between the manufacture of the last item
and the production of the first good item of a new batch
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Set up reduction has a direct influence on the 3M's :-
�Reduced down time
�Increased throughput
�Better utilisation of resource
�Reduced bottlenecking
�Improves utilisation of time
of skilled labour
�Improves utilisation of intelligence
of skilled labour
�Reduces walking time
�Reduces handling time
�Reduces potential for human error
�Allows smaller batch production
�Supports reduced inventory
�Improves inventory turnover
�Reduces material handling costs
�Drives reduction in scrap
MAN MATERIALMACHINE
Set Up Reduction
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Why Reduce Set up Times?
Set up
Reduction
Increased
time for
production
Machines
Materials
Men
� Increased
throughput
� Increased
availability
Small Batch
Production
Increased
mix
Increased bottleneck
utilisation
Reduced product
lead time
Wider range
of products
Reduced
shortages on
assembly
Increased labour utilisation
� Reduced
Inventory
� Reduced
Handling
Reduced waiting on
assembly
Accurate
forecasts
Increased Flexibility
Satisfied
customers
Reduced
Machine Costs
Reduced Labour
Costs
Reduced Storage
Costs
Reduced Handling
Costs
Red
uce
d P
roduct
Cost
s
Cost Benefits
Set Up Reduction
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Set up Reduction & Batch Quantities
Based on individual machine costs - no link to demand
Simple trade off - no indication of hidden costs e.g. increased scrap, redundancy, etc.
EOQ/EBQ is the balance point when total set up and inventory holding costs are minimum.
Batch Size
Inventory holding
cost
Set up or
Ordering cost
Total
cost
EOQ EBQ
Minimum
total cost
Cost
Set Up Reduction
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20%
30%50%
Typical elements of Set Up Time :-
Preparation
� Obtain instructions
� Collect tools from stores
� Check and mount tools
� Check and mount material etc.
Other� Remove work
� Remove tools
� Return tools to stores
� Clean machine etc.
Adjustment
&
Tryout
� First cut
� Dimensional check
� Adjust machine
� Complete first off etc.
Set Up Reduction
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Five Step Approach
1. Preliminary Stage
2. Analysis Phase
3. Identify Internal and External Elements
4. Convert Internal to External Where Possible
5. Reduce Internal and External Times
Set Up Reduction
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Step 3 - Identify Internal and External Elements
External
Tasks that can be done whilst the
machine/process runs on the
previous job.
Examples of external Set up
� Collecting tools and materials.
� Positioning cranes and handling equipment.
� Preparing tools, clamps, bolts, etc.
� Clearing up and cleaning.
� Planning, organising, preparing data, etc.
Internal
Tasks that can only be done
whilst the machine/process is
stopped.
Examples of internal Set up
� Removing guards.
� Removing tools/loading
tools.
� Removing components.
� Adjusting locators etc.
� Inspection and test.
Internal
(Stopped
)
External
(Running
)
Set Up Reduction
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Benefits Summary
Reduced set up Traditional
� Small Batches
� Avoids waste of overproduction
� Minimises Inventory
� Minimises lead times
� Make to Order Philosophy
� Improved production control
� Minimises overheads
� Large Batches / Long Runs
� Encourages overproduction
� Creates buffer inventory
� Long lead times
� Make to Forecast Philosophy
� Complex production control
� High overheads
Set Up Reduction
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7 Quality Tools
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Problem solving tools which can:-
� Help to identify and prioritise problems quickly and more effectively.
� Simplify the decision making process.
� Provide simple but powerful tools for use in continuous improvement activity.
� Provide a vehicle for communicating problems and resolutions throughout the business.
� Provide a way of extracting information from the data collected.
7 Quality Tools
As well as using a systematic approach we
also need to use tools which enable problems
to be defined, data to be collected and
analysed, solutions generated and selected
and the effectiveness reviewed.
Data Collection Techniques
Analysis Techniques
Check Sheets
Histograms and Measles Chart
Run / Correlation Diagrams
Process Charts
Statistical Process Control
Cause and Effect Analysis
Pareto Analysis
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Checksheets
� A simple and effective method of gathering information.
� Ensures consistency of data collected.
� Can be completed whilst doing the normal job.
� Simplifies data collection and analysis.
� Highlights trends.
� Spots problems.
7 Quality Tools
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Histograms and Measles Charts
� Have much in common with the Pareto Diagram.
� Both show graphically the relative number of occurrences
of a range of events.
� Makes important causes become apparent.
� Specification limits can be included to display the capability of
the process.
� Can be used to collect data as it happens.
� Histograms may be vertical or horizontal.
Histograms
7 Quality Tools
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Run & Correlation Diagrams
� Used to explore relationships between events and time, and
between problems and causes (2 variables).
� Both are experimentation techniques to find out when and how
problems arise and how they are rectified.
� Both are simple yet very effective methods.
� Definite trends can be easily detected.
x xx
x
x x
xx x
xxx
xx
xx
PressureT
em
p
AM AM AM AMPM PM PM PM
Defect Rate
7 Quality Tools
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Process Charts
� Lists every step that is involved in the manufacture of a product
or the delivery of a service.
� Excellent tool for identifying wasteful actions.
� It documents the process completely.
� Systematic approach to reveal possible sources of quality and
productivity problems.
� The use of standard symbols aids clarity.
� Commonly used to promote improvements.
� The charts are best assembled using a team
approach (preferably "front line staff").
ReceivePart
Accept
Paint
5
Rework
7 Quality Tools
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Statistical Process Control (SPC)
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Time/Dwell
yellow
paint
Paint thickness
Temperature
Diameter
Width
Depth
Length
Air pressure
SPC is based on taking measurements of a
process, product or feature.
7 Quality Tools
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Cause & Effect Analysis
� Identifies possible root causes of current problems.
� Provides a list of areas for which data will have to be collected and then analysed.
7 Quality Tools
Having defined the opportunity / problem or "effect" in its simplest form, then :
1. Assemble appropriate personnel.
2. Brainstorm the possible causes.
3. Group the causes into broad categories. Typically these might be the 6 M's.
4. Analyse the completed diagram and identify the most likely root cause/s of
the effect.
Measurement Method Machinery
Money Manpower Materials
Out of specification
parts on CNC103
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Pareto Analysis
� Simply a frequency distribution of attribute data arranged by category.
� Commonly known as "ABC Analysis" or "the 80 / 20 Rule".
� Its one of the most effective yet simple tools available.
� An effective ongoing improvement tool.
� Identifies the most significant problems to be worked first.
� Has varying applications for use in manufacturing.
� 80% of the wealth is owned by 20 % of the people
� 80% of holidays are taken during 20% of the year
� 80% of overtime is worked by 20% of the workers
0
20
40
60
80
100
120A B C
7 Quality Tools
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Statistical Process Control
(SPC)
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Definition
"Statistical Process Control (SPC) is a philosophy that uses
statistical techniques in all areas of a company to make continuous improvements in quality and productivity by
reducing variation in any process."
Me
as
ure
me
nt
Time
SPC
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SPC is based on taking measurements of a
process, product or feature.
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8
44
4
A100051
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8
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8
44
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2
8
44
4
Time/Dwell
yellow
paint
Paint thickness
Temperature
Diameter
Width
Depth
Length
Air pressure
SPC
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3+
3(2x4) = 24
=
= (X-X)
n-1
1 2(sigma )
� No previous knowledge of
SPC is necessary.
� You don't have to be a
whiz at maths.
� SPC encourages the team
approach.
� SPC can be applied to any process or activity.
SPC
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Environment
ProcessProduct
or Service
Inputs (4 Ms + E )
All processes/activities are comprised of five inputs
A change in any of the inputs will affect the output
Output
Material
Manpower
Machine
Method
SPC
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Material - Tea, Milk, Sugar, WaterManpower - Yourself
Machine - Kettle, Spoon, Cup
Method - The way you make it
Environment - Kitchen
Example - A cup of tea
We all produce a different result.
SPC
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� Concentrates on stopping the customer receiving out of spec parts.
� It is expensive and labour intensive.
� It's not 100% effective.� It does not look at the cause of the problem.
PROCESS END PRODUCTINSPECTION
SCRAP ORREWORK
CUSTOMER
Fail
Product Pass
Detection concept of Quality :
SPC
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Ideal Quality Concept - control the process not the product
� Uses SPC to identify and control Variation within the process.
� Eliminates scrap and rework.� Involves the process operator, inspection, management and suppliers.
� Concentrates on controlling the process and not the product.
PROCESS CUSTOMERProduct
4Ms + E
InputsMachineryMaterial ManpowerMethodsEnvironment
Inspection on key Inputs
MONITOR & ADJUST
SPC
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Basic Control Chart
Average/ Nominal
Qu
an
tity
Process Improvement
Embodied
Control limits
re-calculated
Time
Upper Control Limit
Lower Control Limit
SPC
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Process capability - CpkExamples assume the process is centred
Spec Width
Process Width
Cpk = 1.5
Spec Width
Process Width
Cpk = 1
Process Width
Spec Width
Cpk = 0.8
Spec Width
Process Width
Cpk = 3
SPC