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Setup Time Reduction
Using: Single Minute Exchange of Die
G.V. Clarke Lean Quality Assoc., LLC
10/22/201
2 1 Copyright-Lean Quality Associates, all rights reserved
In the beginning, there was…STORAGE.
Definitions of TIME
Typical Old procedures /Wastes
EOQ Assumptions / Computation
Improvement process / SMED
Necessary cultural preparation
Basics & Principles
Typical Results
Q & A
www.leanquality.net
10/22/2012 2 Copyright-Lean Quality Associates, all rights reserved
Lean
Definition:
“A systematic approach to identifying and
eliminating waste(non-value-added activities)
through continuous improvement by flowing the
product at the pull of the customer in pursuit of
perfection”
10/22/2012 3 Copyright-Lean Quality Associates, all rights reserved
About Lead Time
“One of the most noteworthy
accomplishments in keeping the price of Ford
products low is the gradual shortening of the
production cycle. The longer an article is in
the process of manufacture and the more it is
moved about, the greater is its ultimate cost.”
Henry Ford, 1926
10/22/2012 4 Copyright-Lean Quality Associates, all rights reserved
Set Up Time
Definition:
“The time between the last good piece off the
current run and the first good piece off the
next run.”
10/22/2012 5 Copyright-Lean Quality Associates, all rights reserved
Historical setup Procedures
Preparation cleaning up completed job
receiving instructions for next job
storing/retrieving tools, parts, materials
checking functionality
Parts removal and attachment
Centering, dimensioning, and setting
tools, dies, jigs, gauges
Trial processing and adjustments
50%
30%
15%
5%
10/22/2012 6 Copyright-Lean Quality Associates, all rights reserved
Wastes in Set-Up Defects
Overproduction
Waiting
Non-utilized
people
Transportation
Inventory
Motion excess
Extra processing
Typically 95% of Total Lead Time is Non-Value Added!!!
10/22/2012 7 Copyright-Lean Quality Associates, all rights reserved
Traditional setup Assumptions
Long runs are necessary
to amortize the cost of
setups
Managing production using
economic order quantities
(EOQ) balances setup costs
and inventory carrying costs
Inventory
10/22/2012 8 Copyright-Lean Quality Associates, all rights reserved
Traditional setup Math
Do these assumptions make sense if setup time
can be significantly reduced?
Fixed Cost
Variable
Cost
Lot/Batch Size EOQ
setup Cost
Inventory Carrying Cost
setup Cost + Inventory Carrying Cost
10/22/2012 9 Copyright-Lean Quality Associates, all rights reserved
Economic Order Quantity (EOQ)
xUnitCostyCostInventCarr
xOrderCosteAnnualUsagx
EOQ
(%)
/)(2
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Effect of SUTR on EOQ
0
200
400
600
800
1000
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
EOQ
EOQ
The effect of Setup Time Reduction on the
Computation of EOQ
10/22/2012 11 Copyright-Lean Quality Associates, all rights reserved
Set Up Improvement Process
A) Document the current setup
B) Analyze the setup and identify ways to reduce or eliminate it (SMED)
C) Implement improvements and monitor results
D) Standardize the improved setup
10/22/2012 12 Copyright-Lean Quality Associates, all rights reserved
The SMED System Step-by-step method to
reduce setup time
Developed by Shigeo
Shingo
Applicable in all
industries
Useful in streamlining
other processes
xchange of
S
M
E
D
ingle
inute
ie
setup in under 10 minutes 10/22/2012 13 Copyright-Lean Quality Associates, all rights reserved
Reducing setup Time
Put the “basics” in place
workplace organization
5 S’s
visual controls
Analyze and improve setup
using SMED
10/22/2012 14 Copyright-Lean Quality Associates, all rights reserved
SMED: Basic Principles
There are two types of setup tasks:
internal (machine down)
external (machine running)
Eliminating or streamlining a setup task
requires a clear understanding of that task’s
real purpose and function
Focus first on no/low cost solutions
The best setup is no setup!
10/22/2012 15 Copyright-Lean Quality Associates, all rights reserved
The Stages of SMED
• Document the current Setup process
• 1-Separate and convert internal elements to external
• 2-Streamline all aspects of setup
operations.
1
10/22/2012 16 Copyright-Lean Quality Associates, all rights reserved
Internal elements to External
Time
Before
Get
tools
Get
parts
Remove
parts
Add
parts Trial Processing
Get
tools
Get
parts
Preset
Parts
Remove
parts
Add
parts
Trial
Processing Internal
External After
10/22/2012 17 Copyright-Lean Quality Associates, all rights reserved
.
Parallel operations
Eliminating adj.
Functional clamps
Mechanization
Planning
Work place Layout
Team/Organize
Training
Pit-Crew Practice
Documentation
Streamline all elements
10/22/2012 18 Copyright-Lean Quality Associates, all rights reserved
Experience with SUTR
Cold Rolling Mill 62 min to 16 min
Grinding Op 35 min to 10 min
Press Brake 16:51 min to 7:08m
Vacuum Evaporator65 min to 22 min
10/22/2012 19 Copyright-Lean Quality Associates, all rights reserved
Additional questions?
Industrial Engr.
Lean & Lean Six Sigma
RABQSA-Principal Auditor
ISO-9000, TS-16949, 17025
(262)-834-8476
www.leanquality.net
10/22/2012 20 Copyright-Lean Quality Associates, all rights reserved
