blog

Set Up Reduction

April 19, 2016 by ESPI

In this series we will discuss Set Up Reduction in a Four (4) Stage Method.  Starting with the underlying concept and moving to Stage 1 – Identify, Stage 2 – Reduce and Convert, Stage 3 – Streamline, Stage 4 – Optimize.

 

DEFINITION

Set up Reduction is defined as: Quick Changeover Time.  That is the time between the last good piece of one production run and the first good piece of the production run after the changeover.

Set up Reduction is a Lean Manufacturing tool that supports manufacturing products after a customer order is received.  It eliminates or reduces non-value added activities in all types of process setups to quickly change from one product to another. This will lead to reduction in batch sizes and shorten lead times eliminating the expense of excess inventory.

BENEFITS OF QUICK CHANGEOVER

  • More frequent changes
  • Smaller batches
  • Lower inventory
  • Better quality
  • Less waste
  • More Flexibility
  • Improved teamwork
  • Less STRESS!!!

 

UNDERLYING CONCEPT

The goal of Set Up Reduction is for reducing waste in a manufacturing process. The idea is to analyze and provide a more rapid and efficient way of changing a manufacturing process from running the current product to running the next product. This rapid changeover is key to reducing production lot sizes and thereby improving flow.  This is largely achieved by first classifying each setup step as either Internal or External (Internal steps are those done while the process is inactive and External steps are done while the process is operating).  Next is to convert the Internal steps to External steps. If we want to reduce the time the process is non-operational, we need to reduce the time associated with the process being inactive. The quickest way to achieve this is to do as many of these steps as we can while the process is operational.

 

IntExtAct

Read More

What you need to ask before you buy.

April 19, 2016 by ESPI

At the time of final negotiations, run down this list before completing the transaction:

 

  • Confirm pricing to be certain all software costs, licenses, installation, training and any other miscellaneous fees are included.
  • Ask for a concrete schedule for installation and implementation – don’t compromise on the delivery!
  • Request details about who the vendor will be assigning to your project. Insist on qualified and experienced software consultants who have the capacity to see your project through to completion.
  • Confirm that the vendor will work hand-in hand with external consultants. Having 3rd party oversight can expedite implementation and ensure a smooth transition.

Organizations need to understand that a new system is not a silver bullet, but it is a critical piece of infrastructure supporting your business. With careful planning and due diligence, you will find a system that fits your business objectives, allows for flexibility and meet your strategic goals to fuel your growth.

Join us next week as we start a NEW series
Read More

Stage 1 – IDENTIFY

April 19, 2016 by ESPI

Stage 1 – IDENTIFY

With any process analysis, the first step is to observe. All elements of the changeover need to be observed and recorded. This allows a baseline to be established so that the level of improvement can be determined and also provides the raw information that will be utilized -during the process.

 

The best technique to use at this stage is video recording. Staff usually has no problems with being videotaped while they perform a set-up provided the importance and process of set-up time reduction has been properly explained. The video will allow the set-up to be replayed as many times as is necessary to analyze and improve the process.

 

Stage 1 Tools

  • Video Recording Device
  • Stopwatch
  • Set Up Reduction Worksheet
  • Area Layout Map

The Setup Reduction Worksheet is used to document the events performed during the setup. The worksheet provides a time stamp for each event during the setup and is used to identify internal and external events.

 

SetupReduction

 

The Area Layout Map allows you to make a spaghetti diagram creating a visual map of the actual flow.  This is to be used in conjunction with the Setup Reduction Worksheet.

SpaghettiDiagram

Steps

  • Record the processes on the Setup Reduction Worksheet and ask questions if not clear on the activity.
  • Start at the beginning of the first process. Use directional arrows for the routes that are traced on the Area Layout Map. Record all steps and elapsed times on the Setup Reduction Worksheet.
  • Do not leave out any flow movement even if the paper becomes cluttered and difficult to follow. This will most likely indicate areas of opportunity.
  • Record the amount of time within each activity.
  • Show the areas where materials and tools are stopped, staged, held, inspected and picked up. Look for point-of-use opportunities for materials, tools, and paperwork.
  • Record the names of those involved, dates, times, and other relevant information.
  • Calculate the distance, times, shift, starts, stops, to provide baseline performance.
Read More

Happy Thanksgiving

April 19, 2016 by ESPI

Thanksgiving2014

Read More