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Setup Reduction -- Creating More Production Time Dr. Richard A. Wysk rwysk@psu.edu http://www.engr.psu.

Setup Reduction -- Creating More Production Time Dr. Richard A. Wysk rwysk@psu.edu http://www.engr.psu.edu/cim Fall 2007. Objectives. To be able to identify internal and external process elements To be able to apply methods improvements techniques to manufacturing

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Setup Reduction -- Creating More Production Time Dr. Richard A. Wysk rwysk@psu.edu http://www.engr.psu.

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  1. Setup Reduction -- Creating More Production TimeDr. Richard A. Wyskrwysk@psu.eduhttp://www.engr.psu.edu/cimFall 2007

  2. 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

  3. 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

  4. JIT -- Speed is everything! Some Just in time models Buying bread Buying milk Buying “take-out”

  5. Exercise • What are the most important factors that contribute to the production time (average time required to produce a single unit/product)?

  6. In Industry Between .05% and 5% of the time Value is being added to a product

  7. What are the Value added activities at PSU Inc.? Receiving -> Material handling -> Machining -> Assembling -> Packaging

  8. 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?

  9. Producing a product Production time (per lot) = setup time (per lot) + manufacturing time (per lot)

  10. Producing a product Manufacturing time (per piece) = material handling and locating time (per piece) + manufacturing time (per piece)

  11. Simple CNC Example • New batch of parts arrives • 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

  12. 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

  13. This can be > 30% of the TOTAL TIME TO PRODUCE A LOT A look at SETUP SETTING UP THE MACHINE 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)

  14. 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”

  15. 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.

  16. 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.

  17. 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

  18. 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

  19. 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

  20. 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

  21. Examples of Improved Methods

  22. 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!

  23. Reduce the amount of turns required in order to activate the screw.

  24. Reduce the amount of screw turns and eliminate the tool!

  25. Areas with potential benefit • Screws and screw fasteners • Tedious manual activities • Power tools can be appropriate • Connectors • Others????

  26. Currently changeover is done with these tools

  27. Currently changeover is done with these tools

  28. How about power tooling?

  29. How about cordless power tooling?

  30. Exercise Describe what methods, improvements, you could make to the setup/change over activity for the a personal activity?

  31. Questions?

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