1 / 37

Readings

Setup Reduction -- Creating More Production Time Dr. Richard A. Wysk rwysk@psu.edu http://www.engr.psu.edu/cim. Readings. Singo Shingeo, A Revolution in Manufacturing-The SMED-Single Minute Exchange of Dies-System , Productivity Press, 1981.

naiara
Télécharger la présentation

Readings

An Image/Link below is provided (as is) to download presentation Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author. Content is provided to you AS IS for your information and personal use only. Download presentation by click this link. While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server. During download, if you can't get a presentation, the file might be deleted by the publisher.

E N D

Presentation Transcript

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

  2. Readings • Singo Shingeo, A Revolution in Manufacturing-The SMED-Single Minute Exchange of Dies-System, Productivity Press, 1981. • Chapter 18 of Computer Aided Manufacturing, Wang, H.P., Chang, T.C. and Wysk, R. A., 3rd Edition (2004 expected) http://www.engr.psu.edu/cim/active/ie450ho1.pdf

  3. Make it better!Make it faster!Make it cheaper!

  4. 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

  5. ExerciseReadiness Assessment Test A.K.A. RAT AS A INDIVIDUAL, prepare a justification of reducing set-up time. • What is the value of reducing the set-up time? • How can set-up reduction activities be justified? • What are the two type of elements of set-up? Open Book / Open Notes

  6. 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

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

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

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

  10. 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?

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

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

  13. 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

  14. 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

  15. 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)

  16. 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”

  17. 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.

  18. 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.

  19. 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

  20. 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

  21. 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

  22. Exercise (5 minutes) As an individual, describe a process that you know well (from work, food preparation, office activities…) Identify the internal and external elements for setup or work changeover.

  23. 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

  24. Examples of Improved Methods

  25. 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!

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

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

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

  29. Currently changeover is done with these tools

  30. Currently changeover is done with these tools

  31. How about power tooling?

  32. How about cordless power tooling?

  33. SMED is employee driven • Train Area supervisors and operators • Some implementation with outside consultant • Most implementation within your company

  34. Questions?

More Related