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Setup reduction / quick changeover

Setup reduction / quick changeover. Setup Time Drives Batch Size:. The Economic Order Quantities (EOQ) model determines the most economic lot/batch size for a production run. Changeover Cost + Inventory Carrying Cost. Variable Cost. Inventory Carrying Cost. Changeover Cost. Fixed Cost.

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Setup reduction / quick changeover

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  1. Setup reduction / quick changeover

  2. Setup Time Drives Batch Size: The Economic Order Quantities (EOQ) model determines the most economic lot/batch size for a production run. Changeover Cost + Inventory Carrying Cost Variable Cost Inventory Carrying Cost Changeover Cost Fixed Cost EOQ Increasing Lot/Batch Size

  3. Preparation, after-process adjustment, checking, return to storage of parts, tools, fixtures Removing parts, blades, jigs, etc.; mounting same for next lot Machine settings, measurements Making trial pieces and adjusting Setup Reduction or Quick Changeover • Definition:Minimizing the time from last good piece of the current product run to first good piece of the next (different) product run. • STEPS IN A CHANGEOVER: (1) Preparation; (2) Remove/Install Tooling; (3) Change Machine Settings; (4) Make Trial Pieces & Adjust. Percent of time of changeover 30% 50% 15% 15% 5%

  4. Quick Changeover: Visual Controls

  5. Quick Changeover Clearly labeled cutter size and style All regular router cuts needed in this workcell stored at router table.

  6. Three Stages of Quick Changeover 1. Separate Internal and External Setup 2. Convert Internal Setup to External Setup 3. Streamline Internal and External Elements Setup Reduction

  7. Stage 1: Separate Internal and External Setup Separate Internal and External Setup • Develop and implement changeover checklists. • Perform function checks on parts and tools before changeover • Isolate transportation of tools, parts, and materials. Convert Internal Setup to External Setup Streamline Internal and External Elements Setup Reduction

  8. Stage 2: Convert Internal Setup to External Setup Separate Internal and External Setup • Prepare operating conditions in advance • Standardize functions • Use intermediary jigs Convert Internal Setup to External Setup Streamline Internal and External Elements Setup Reduction

  9. Stage 3: Streamline Internal and External Elements Separate Internal and External Setup • Implement parallel operations • Eliminate the need for adjustments • Use functional clamps • Mechanize functions Convert Internal Setup to External Setup Streamline Internal and External Elements Setup Reduction

  10. Transition Steps to Quick Changeover Preliminary Step 1 Step 2 Step 3 Internal and External Setup not differentiated Separate Internal and External Setup Convert Internal Setup to External Setup Streamline all aspects of Setup operations Ext Process Walk Analysis Ext Preparation Standardization Jigs Ext Management of parts and tools Ext Int Ext Int Ext Int Parallel operations Clamps Less adjustments Mechanization Int Int Int

  11. No/Low Cost Solution: Positioning Pins Positioning Pins Positioning Pins

  12. No/Lo Solution: One-Turn Methods Pear-Shaped Hole Method Tighten Here Attach and Remove Here

  13. Other Functional Clamps

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