SETUP OPERATIONS

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SETUP OPERATIONS

• A setup operation (or simply setup) is the
  preparation or after adjustment that is performed
  once before and one after each lot is processed.

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Basic Steps in a Setup Operation

• 1. Preparation, After Process Adjustments,
  Checking of Materials and Tools
• 2. Mounting and removing blades, Tools, and Parts
• 3. Measurements, Settings and Calibrations
• 4. Trial Runs and Adjustments

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SETUP The Root of Many Problems

• Long delivery times
• Poor quality
• Higher WIP
• Longer cycle times
• Obsolescence
• Larger raw material stores
• Larger finished goods stores
• Make to stock
• Lost competition with lean competitors

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Setup time gt 0 ? batch size gt 1

• The famous EOQ formula indicates this
• 2S D Q
  h
• Where, S is setup cost, D is demand rate, and h
  is unit inventory holding cost.

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Effects of Setup Reduction

• The total cost of building batches in
  anticipation of demand is given by
• TC S(D/Q) H(Q/2)
• Where, Ssetup cost, H holding cost, Qbatch
  size.
• The graph of TC and its two components are given
  below.

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Effects of Setup Reduction
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Effects of Setup Reduction
Annual Cost
If Snew lt Sold
Total cost SD/Q hQ/2
Q
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Components of Setup TimeExternal vs. Internal

• Internal Setup This part of the setup operation
  can only be done when the machine is shut down.
  For example, a new die can only be attached to a
  press when the press is stopped.

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Components of Setup TimeExternal vs. Internal

• External Setup This part of the setup operation
  can be done while the machine is still running.
  For example, bolts to attach to the die can be
  assembled and sorted while the press is operating.

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Components of Setup TimeSeparating Internal and
External Setup

• Certain tasks can be done before machines are
  stopped for changeover. These include lining up
  the right people, preparing parts and tools,
  making repairs, and bringing parts and tools
  closer to the equipment.
• It is surprising however, that often these tasks
  are done after the machine has been stopped
  instead of while it is still running the previous
  lot.
• A checklist that lists everything required to
  set up and run the next operation will minimize
  those external setup elements that are performed
  as internal elements.

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Components of Setup Time Separating Internal and
External Setup

• Checklist
• Tools, specifications, and workers required
• Proper values for operating conditions such as
  temperature pressure, current, and feed rate
• Correct measurements and dimension required for
  each operation
• Function checks before the setup

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Components of Setup Time Separating Internal and
External Setup

• Improve the transport of parts and tools. Make
  sure that during this transport the machine is
  still running.

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Components of Setup TimeConverting Internal
Setup to External Setup

• 1. Look closely at each individual function in
  your setup process and decide which functions, if
  any, can be standardized.
• 2. Look again at the functions and think about
  which can be made more efficient by replacing the
  fewest possible parts.

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Components of Setup TimeImproving the Internal
setup

• The quickest way to replace something, of
  course, is to replace nothing at all - or as
  little as possible.

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Components of Setup TimeImproving the Internal
setup

• Function standardization
• Standardize clamping operations
• Use jigs to center dies
• Use die cassette systems
• Use intermediary jigs
• Implement parallel operations
• Use functional clamps
• Eliminate adjustments
• Fix numerical settings
• Make centerlines and reference planes visible
• Use limit switches, sensors and other warning
  devices

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Single Minute Exchange of DiesSMED

• The philosophy of SMED was borne in 1950 by
  Shigeo Shingo while he was conducting efficiency
  improvement survey at Toyo Kogyos Mazda Plant in
  Hiroshima.

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Single Minute Exchange of DiesSMED

• Shingo proposed the following conceptual stages
  for SMED
• Preliminary Stage Internal and external Setup
  conditions are not distinguished
• Stage 1 Separating internal and external setup
• Stage 2 Converting Internal to external setup
• Stage 3 Streamlining all aspects of the setup
  operation

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Single Minute Exchange of DiesApplying SMED to
Internal Operations

• Implement parallel operations
• Use functional clamps
• One turn attachments
• Pear-shaped holes for clamping
• U-shaped washers for clamping
• Split thread screws for one turn operations
• U-slots for attachment
• Clamping instead of screwing
• One motion clamping devices
• Interlocking devices

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Single Minute Exchange of Dies Applying SMED to
Internal Operations

• Elimination of adjustments
• Fixing numerical settings
• Make centerlines and reference planes clearly
  visible
• Use sensors and limit switches
• Use mechanization (only after exhausting other
  means) in streamlining the setup.
• Use the energy provided by the machine to speed
  up setup operations

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SMED Example
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SMED Example
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SMED Example