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Smed tips Smed tips Document Transcript

  • SaAugust 2010 ve Se $3 e ,00 pa 0 ge ,0 www.changeover.com 787-550-9650 info@changeover.com 4 00 John Henry’s Lean Changeover Newsletter ServicesSee more & subscribe at www.changeover.com Changeover.com Workshops Services OfferedSOME THOUGHTS ON…  Workshops Changeover/SMED SCALES & POINTERS Changeover Made ESEE Effective TroubleshootingThose of you who have been some bad. Here are a few of Vibratory feedersto my workshops, read this the lessons I’ve learned:newsletter or know me at all Custom trainingknow the tremendous impor- 1) Scales should be either met-tance I place on making pre- ric or, if inch, decimal. Most Operational Excellencecise changeover settings. Ex- inch scales are in fractions ofactly! Is the fourth component an inch and can be hard to Changeover assessmentof the ESEE methodology. read. Even when read cor- rectly, it can take time to figure Package & equipment designThis month I out which line ESEE machine certificationwant to talk us- represents 10- Technical writinging scales or 9/16. Speechifyingrulers in setup. Oregon RuleA scale is a has a wide va-piece of metal riety of scales Changeoveror plastic that is p r i n t ed on Madedivided into plastic film with ESEE (easy)segments. an adhesiveMarkings may backing. Their Changeover Made ESEE is a 2be inch, metric, scales are day workshop featuring both con-degrees or arbi- available in ceptual and hands-on training for operators, mechanics, engineerstrary units. When used in decimal inch as well as metric. and others involved in change-setup, the scale is affixed to a over.stationary component of the 2) In most setup applications,machine and with a pointer on the scale is not measuring any- For detailed information call Johnthe adjustable component. Or thing. It is simply a number to Henry at 787-550-9650 or johnhenry@changeover.comvice-versa. They are a simple match the pointer too. If possi-and effective way to put preci- ble, standardize all scales tosion into an adjustment if prop- use the same gradations, ei-erly applied and used. ther inch or metric.I’ve seen a lot of applications 3) Perhaps the biggest prob-over the years, many good, lem I see with the use of scales © Copyright 2010 by John R Henry, all rights reserved. Permission is granted to copy and circulate this newsletter provided that it remains intact. For permission to republish articles in other venues, contact johnhenry@changeover.com
  • John Henry’s Lean Changeover NewsletterPage 2 See more & subscribe at www.changeover.comSOME THOUGHTS ON… (cont)is the pointers. One manufacturer puts a The scale is only half of the tool. The pointervery nice scale on all their machines for is the other half and every bit as important.height adjustment. However, there is nopointer, making the scale little more than a 4) Scales are only as good as their calibra-decoration. Another popular machine uses a tion. The appropriate scale reading must besquare steel tube running the length of the determined for each product and setup. Thismachine to mount clamps. The bar is nicely then needs to be documented and madeetched with a scale but there is no indication available to the mechanic or operator. If theyof which side of the clamp is to be read. A don’t know what the value is, they can’t setsimple punch mark solves this problem. it. 7) If only a few products are normally run, custom scales can be used. One plant with 6 different products mounted metal strips with a mark for each product size. The pointer has a slot in it. All scales (as well as all other setup adjustments and changeparts) are colorcoded. In setup, the appropriate colored mark is centered in the4) I’ve seen a machine with an adjustablepointer. Pointers must be rigid and fixed inposition. If they move, their whole point islost.5) A fairly common problem is that thepointer is not close to the scale. This causes pointer slot. In this plant the operators do not even need a setup sheet. They simply set everything to green Scales are a valuable setup tool, in part be- cause they are so simple and straightfor-reading error due to parallax. ward.© Copyright 2010 by John R Henry, all rights reserved. Permission is granted to copy and circulate this newsletter provided thatit remains intact. For permission to republish articles in other venues, contact johnhenry@changeover.com
  • John Henry’s Lean Changeover Newsletter Page 3 See more & subscribe at www.changeover.com SOME THOUGHTS ON… (cont) be? Don’t let this valuable tool This simplicity can work be anything less. against them by causing peo- ple to take them for granted. Are your scales all they can What do you think? Please let me hear from you at johnhenry@changeover.comTIP OF THE MONTH...MAGNIFYING POINTERS A few months ago I had sources but the only place we pointed to the Saw Stop as an have identified so far is on the interesting safety device. For Saw Stop machine. Join the Changeover/ those who don’t remember, this is a device that instantly You can see it in the video SMED group at stops a circular saw blade on "ICS Product features" at the contact with a finger or other Sawstop site. They use it for www.linkedin.com body part. precision setting of the rip fence. If you want to know how in- stantly, check out the video us- I have not contacted Sawstop ing a sausage to simulate a yet but I would imagine that the finger. http://sawstop.com/ lens is available from their howitworks/how_overview.php parts department. In a recent discussion in my I suspect that it is commercially Changeover/SMED group on available in this and other con- LinkedIn, someone had men- figurations but have been tioned magnifying pointers. searching and cannot find it This is a plastic piece with a anywhere. lens molded into it. Across the center of the lens is a hairline. Does anyone know where it The lens embiggens the scale might be purchased? making it easy to read the markings. The hairline is on the If so, drop me a note at back, reducing the possibility of johnhenry@changeover.com parallax error. so I can share the info here. I had asked for pictures or © Copyright 2010 by John R Henry, all rights reserved. Permission is granted to copy and circulate this newsletter provided that it remains intact. For permission to republish articles in other venues, contact johnhenry@changeover.com
  • August 2010 www.changeover.com 787-550-9650 info@changeover.com John Henry’s Lean Changeover NewsletterSee more & subscribe at www.changeover.comYou know changeover is expensive but do you know how expensive?See how many dollars per year even a 1 minute reduction in changeover time is worth.Use this changeover calculator below to calculate how much changeover costs your company. Sim-ply enter the relevant numbers for your plant in A, B & C and do the math for D, E & F. The numberswill shock you.For a self-calculating Excel spreadsheet e-mail johnhenry@changeover.comStart cutting these costs NOW! Call John Henry at Changeover.com 787-550-9650. “If not now, when? If not you, who?” A. Changeovers per week (#) B. Changeover duration incl. startup (min) C. Downtime cost per hour ($) D. Changeover cost per week (A X B X C /60) E. Changeover cost per year (D X 50) F. Annual savings per minute of changeover reduction (A X C/60 X 50) EXAMPLEA plant performs 1 changeover per day taking on average 2 hours eachAssumes 5 day week, 50 weeks per year A. Changeovers per week (#) 5 B. Changeover duration incl. startup (min) 120min C. Downtime cost per hour ($) $10,000.00 D. Changeover cost per week (A X B X C /60) ( $100,000.00) E. Changeover cost per year (D X 50) ($5,000,000.00) F. Annual savings per minute of changeover reduction (A X C/60 X 50) $41,666.67