1. Analyze Improve Define Measure Control Improve L EAN S IX S IGMA L EAN S IX S IGMA Ensuring Value (Part 2)  Quick Changeover / Set-up Reduction

2. Analyze Improve Define Measure Control Improve L EAN S IX S IGMA L EAN S IX S IGMA Set-Up Reduction  Set-Up Reduction Introduction  Effect of Set-Up Reduction  The Four-Step Method  Implementing Set-Up Improvements RD010402

3. Improve Module 13 3 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

4. Improve Module 13 4 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

5. Improve Module 13 5 Production DowntimeRamp-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

6. Improve Module 13 6 Set-Up Time Defined 50% 30% 5% 15% Last Good Product of Run First Good Product(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

7. Improve Module 13 7 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 1 st piece product is made Inspect / measure test piece or 1 st piece

8. Improve Module 13 8 Advantages 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,,

9. Improve Module 13 9 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

10. Improve Module 13 10 Step 1 of 4 STEP 1 Document the set-up and separate events into internal or external STEP 3 Streamline internal events (Simplify, Reduce, Eliminate) STEP 2 Convert Internal to External events STEP 4 Eliminate adjustments internal to the set-up Step 1 is done first to attain benefits quickly D, M A, I I I, C xx “Corresponding” DMAIC phase for a stand-alone Set-Up Reduction project

11. Improve Module 13 11 Step 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

12. Improve Module 13 12 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

13. Improve Module 13 13 Step 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

14. Improve Module 13 14 Step 1A: Creating and Using the Area Layout Punch Press #1465 Tool Carousel Controls Tool/Die & Fixture Room Hardware Cage Production Control Quality Control Hand Tool Cabinet Note: To enhance area layout readability, consider numbering each traffic line and / or use multiple area layout pages

15. Improve Module 13 15 Step 1A: Area Layout (Example) Does this appear efficient? This set-up could probably be streamlined with better storage and location of needed items!

16. Improve Module 13 16 Step 1A & 1B: Set-Up Documentation Worksheet ITEM # _____________________________ See copy in Excel format within Appendix A

17. Improve Module 13 17 Step 2 of 4 STEP 1 Document the set-up and separate events into internal or external STEP 3 Streamline internal events (Simplify, Reduce, Eliminate) STEP 2 Convert Internal to External events STEP 4 Eliminate adjustments internal to the set-up

18. Improve Module 13 18  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

19. Improve Module 13 19 Step 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.

20. Improve Module 13 20 Step 2: Improvements Worksheet (Example) See copy in Excel format within Appendix A

21. Improve Module 13 21 Step 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

22. Improve Module 13 22 Step 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.

23. Improve Module 13 23 CRESCENT WRENCH SCREWDRIVER ALLEN WRENCH Step 2: Applications of Step 2  Checklists  Check Tables or Shadow-boards  Battle Plans  Functional Checks  Improving Transportation

24. Improve Module 13 24 Step 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

25. Improve Module 13 25 Step 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 o Review check table o Retrieve change parts o Tools clean and in working order o Change parts clean and in working order o Functional checks completed Part #: 432543

26. Improve Module 13 26 Step 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. CRESCENT WRENCH SCREWDRIVER ALLEN WRENCH

27. Improve Module 13 27 Step 2: Battle Plans  Developed daily  Everyone involved in set-up and operation must know battle plan

28. Improve Module 13 28 Step 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

29. Improve Module 13 29 Step 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 min 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 External 11 min NEW - 11 min External events for the next run are to be performed while the prior part is being run.

30. Improve Module 13 30 Step 3 of 4 STEP 1 Document the set-up and separate events into internal or external STEP 3 Streamline internal events (Simplify, Reduce, Eliminate) STEP 2 Convert Internal to External events STEP 4 Eliminate adjustments internal to the set-up

31. Improve Module 13 31 Goals of Step 3  Goal: Streamline internal set-up by streamlining the internal set-up steps by: Simplifying Movement Reducing Movement Eliminating Movement

32. Improve Module 13 32 Step 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

33. Improve Module 13 33 Step 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 Bolt with 12 Threads

34. Improve Module 13 34 Step 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 minutes Bolt with 12 Threads BUT only one turn to secure!

35. Improve Module 13 35 Step 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%

36. Improve Module 13 36 Step 3: Nut & Bolt Improvement Methods Reduce Number of Screws U-Slot Method Clamps Snap Method Magnets Pear Shaped Hole Method Single Motion Connections Use of Cams Toggle Clamps One-Turn Method Use Only 1 Type/ Size of Fastener

37. Improve Module 13 37 Step 3: One-Turn Procedures Eliminate lost nuts, bolts, different-size nuts and bolts 8 bolts to be removed0 bolts removed 8 half-turns to loosen NEW – 1.6 minOLD – 18 min

38. Improve Module 13 38 Step 4 of 4 STEP 1 Document the set-up and separate events into internal or external STEP 3 Streamline internal events (Simplify, Reduce, Eliminate) STEP 2 Convert Internal to External events STEP 4 Eliminate adjustments internal to the set-up

39. Improve Module 13 39 Step 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.

40. Improve Module 13 40 Step 4: Test Runs Are Typically 50% of Set-Up Time Test Runs 50% Test Runs 50% Preparation 30% Preparation 30% Set-Up 5% Set-Up 5% Measurements and Settings 15% Measurements and Settings 15%

41. Improve Module 13 41 Step 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

42. Improve Module 13 42 Step 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

43. Improve Module 13 43 Step 4: Pin and Place Method on Conveyor Rails BeforeAfter 34 Minutes 8 Minutes Screws Slide & Adjust Set Rail Fixed Pins One fixed side plus pre-determined settings on the other side Completely variable placement on both sides

44. Improve Module 13 44 Step 4: Pin & Place Method Conveyor Rails Results 34 min 8 min 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

45. Improve Module 13 45 Step 4: Centering Method Fixture Machine Center Adjustments Machine Base Fixture Machine BaseCentering Ball Or Notch Machine Center Before After

46. Improve Module 13 46 Step 4: Centering Method Results Load & cut part Correct dimensions Make adjustments Start production Place fixture onto base Take measurements 8 min Before Start production Place fixture onto base centering using centering ball 1 min After Average 2 Scrapped Parts 0 Scrapped Parts

47. Improve Module 13 47 Step 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 adjustments Up 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!

48. Improve Module 13 48 Step 4: Machining Setting Checklist  Provide vehicle for converting settings based on intuition to settings based on fact! Milling Machine M-25 Setting Checklist