1. Setup Reduction Module
The benefits of quick changeover
Meet customer needs
CIPP Buyouts (more time for output)
Smaller lot sizes
Reduced inventory
Reduced cost
On time delivery
Production smoothing
Waste elimination
Higher quality
Increase cash flow
Flexibility in scheduling
Reduce lead time
Increase profitability

2. Definition of Setup Time
The amount of time taken to change a machine from the last part of a production lot to the first good part of the next production lot.
Including gauging and fine tuning
Clock time, not labor time.

3. Typical Setup Process Gathering necessary items 25%
Exchanging parts 10%
Positioning parts 20%
Making adjustments 45%
The biggest opportunity for improvement is in reducing the look time for gathering items and eliminating the need to make adjustments.

4. Setup Reduction Terminology
Internal Setup
Work that must be done while the machine is stopped
External Setup
Work that can be done while the machine is running
Equipment List
List of all tools, gages, fixtures, etc. necessary to complete the setup
Intermediate Jigs
Plates, spacers, or frames that eliminate the need to make major changes during the setup
SMED
Single minute exchange of dies-----the goal of all setup reduction projects

5. Setup Reduction
Step 1
Separate the work that must be done while the machine is stopped (internal setup) from the work that can be done while the machine is running (external setup).
Create a list of all setup activities and label whether they are internal or external.
Example:
Move material into work area E
Loosen 6 cap screws I
Remove chuck jaws I
Remove work stops I
Change inserts I
Get part prints E

6. Setup Reduction
Step 2
Reduce internal setup by doing more work externally. Determine the baseline time necessary to complete each setup element. Next determine the true function and purpose of each internal setup element and brainstorm ways to do them externally or eliminate.
Prepare dies, fixtures, and gages outside the machine environment while the old parts are still being machined. Necessary tools should be gathered and laid out in proper sequence of use while the machine is still running old parts. Use setup carts when appropriate.
Minimize the number of adjustments by standardizing, using dowel pins, and precision locators etc. Duplicate tooling and equipment can be pre-adjusted while the old parts are running.

7. Setup Reduction
Step 3
Streamline all internal and external elements that have been recognized as still necessary.
Make sure that the setup elements are being done in the most advantageous order and means possible. Simplify or eliminate the need for adjustments and tweaking by developing gadgets, set blocks. Use quick change tooling such as chuck jaws, commonize nuts, bolts, and hardware.
Use a setup team approach if necessary to reduce the time the machine must be down during the setup.
Involve many disciplines such as toolmakers, processors, operators, quality, and IE’s

8. Setup Reduction
Step 4
Fine tune all elements of the setup by training the operators and timing the new setup process. Again look for ways to reduce the time of the longest elements.
Retime and observe until the operator has the new process nailed.
“Operating Room” analogy
Once the new setup procedure is defined create a SOP (Standard Operating Procedure) that is laminated and posted at the machine for use by all operators.

9. Key Activities Set an improvement target Observe the setup as is
Brainstorm improvements
Create action item list
Prioritize implementation
Assign Tasks to team members
Develop new procedure
Perform & time new procedure
Train all operators
Repeat the setup---practice and retime until all operators are efficient at the new procedure
Create SOP, laminate and post

10. Setup Reduction Techniques
Use color coded equipment
Commonize components
Commonize wrenches
Use air or cordless tools
Use hydraulic or air clamping
Use digital pictures to document SOP
Use precision locators
Die carts
Shadow boards
Organize and label all equipment
Use a video camera
Use PERT to define the critical path
Eliminate the setup altogether by using dedicated machines if possible