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SBS - SMED Training (Set Up Reduction)

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SBS - SMED Training (Set Up Reduction)

  1. 1. SET-UP Reduction Workshop SS MM EE DD 1 Welcome !!! The Kaizen SMED Workshop
  2. 2. SET-UP Reduction Workshop SS MM EE DD 2 • Relentlessly Deliver to Our Customers Consistently Superior Value that Enables Symmetry Medical to Grow Better and Faster • Be Considered by All as the #1 Supplier, Employer and Investment of Choice • Become Clearly Recognized as the Industry’s Leader in Earnings and Sales Growth, as Well as a Premier Company, Distinctive and Successful in Everything we do SBS Mission Statement
  3. 3. SET-UP Reduction Workshop SS MM EE DD 3 Takt / Flow/ Pull Lean Mfg Six Sigma Total Quality WasteElimination(7Wastes) VariationReduction JIT TPM SMED Part Family / Process Cells 5 Ss (Housekeeping) & Visual Management Employee Involvement Defect Collection / Tracking & RCCA Industry’s ISO Quality System Green Belt - PQM Process Standardization BB - DOE Management Commitment 6σ 6σ 6σ Using an Inclusive Approach Team WorkTeam Work SPFSPF SMED Lean Sigma Strategy
  4. 4. SET-UP Reduction Workshop SS MM EE DD 4 Single Minute Exchange of 100 10 200 40 0 Dies, tools & fixtures 30 0 SSingleingle MMinuteinute EExchange ofxchange of DDiesies KKaizenaizen
  5. 5. SET-UP Reduction Workshop SS MM EE DD 5 SSingleingle MMinuteinute EExchange ofxchange of DDiesies KKaizenaizen Kiazen Team Ground RulesKiazen Team Ground Rules •Keep an open mind to change •Maintain a positive attitude •Never leave in a silent disagreement •Practice mutual respect every day •Treat others as you want to be treated •One person, one voice - no position rank •There’s no such thing as a dumb question •Understand the process and Just Do It!
  6. 6. SET-UP Reduction Workshop SS MM EE DD 6 Agenda ACTION • Why SMED • Terms and Concepts • Analyzing Set-Up Operations • Separate Internal and External • Checklists • Perform Function Checks • Improve Transport of Dies and Tools • Action
  7. 7. SET-UP Reduction Workshop SS MM EE DD 7 Why SMED ? • Optimize machine time • Make one-piece flow possible • Reduce leadtime
  8. 8. SET-UP Reduction Workshop SS MM EE DD 8 Set-up time and flexible manufacturing Traditional approach Flexible manufacturing Priority Strategy Set-up time Basic Hours Enlarge batches Less determining Lead time Quick reaction Inventory level Reduce batches Very important
  9. 9. SET-UP Reduction Workshop SS MM EE DD 9 This is a problem Given little consideration Traditional approach Present reality New approach Batches Set-up times Big batches Batch reductions One-piece flow Attack head-on SMED and batch size
  10. 10. SET-UP Reduction Workshop SS MM EE DD 10 Batch, SMED and Leadtime 50 30 25 9 5 Batch sizeNum ber ofbatches M achining : tim e per unit(hrs) M achining tim e / batch Set-up tim e/batch Inventory (equals 1 batch) Leadtim e (hrs) 10 10 10 10 10 10 5 5 1 1 1 2 2 10 10 4 4 4 4 4 40 20 20 4 4 10 5 5 1 1 Batch Set-up 10 10 Batch Set-up 5 10 Batch Set-up 5 5 Batch Set-up 1 1 Batch Set-up 1 5 M onthly requirem ent 10 10 5 5 1 A B A + B Today Tomorrow P R O G R E S S I O N
  11. 11. SET-UP Reduction Workshop SS MM EE DD 11 Defects Delivery DelaysProductivity Profitability Before SMED After SMED Why SMED ?
  12. 12. SET-UP Reduction Workshop SS MM EE DD 12 Summary Number of models Quantities by configuration Batch sizes Set-up frequency Single Minute Exchange of Dies lead time One-piece flow and
  13. 13. SET-UP Reduction Workshop SS MM EE DD 13 ACTION • Why SMED • Terms and Concepts • Analyzing Set-Up Operations • Separate Internal and External • Checklists • Perform Function Checks • Improve Transport of Dies and Tools • Action
  14. 14. SET-UP Reduction Workshop SS MM EE DD 14 Quick Changeover has many meanings depending upon what we are talking about, so lets define some terms: SSingleingle MMinuteinute EExchange ofxchange of DDieie
  15. 15. SET-UP Reduction Workshop SS MM EE DD 15 Changeover Time: The time between the last good piece off one run and the first good piece off the next run!!! SSingleingle MMinuteinute EExchange ofxchange of DDieie
  16. 16. SET-UP Reduction Workshop SS MM EE DD 16 INTERNAL SET-UP • Aspects of the SET-UP that can ONLY be performed while the machine is stopped. (Mounting and removing dies) • Minimize by separating from external, then find ways to reduce or convert to external. SSingleingle MMinuteinute EExchange ofxchange of DDieie
  17. 17. SET-UP Reduction Workshop SS MM EE DD 17 EXTERNAL SET-UP • Any aspect of the SET-UP that can be conducted while the machine is in operation (Transporting old dies to storage, conveying new dies to the machine, getting raw material, getting tools / gages, finding bolts / clamps). SSingleingle MMinuteinute EExchange ofxchange of DDieie
  18. 18. SET-UP Reduction Workshop SS MM EE DD 18 • A changeover that can be accomplished in less than ten minutes. Single Digit Changeover (SDC) SSingleingle MMinuteinute EExchange ofxchange of DDieie
  19. 19. SET-UP Reduction Workshop SS MM EE DD 19 One Touch Changeover (OTC) • A changeover that can be accomplished in less than one minute and is activated by a proactive action such as pushing a button. SSingleingle MMinuteinute EExchange ofxchange of DDieie
  20. 20. SET-UP Reduction Workshop SS MM EE DD 20 No Touch Changeover (NTC) • A changeover that can be accomplished in less than a minute automatically. SSingleingle MMinuteinute EExchange ofxchange of DDieie
  21. 21. SET-UP Reduction Workshop SS MM EE DD 21 ACTION Preliminary Internal and external setup not differentiated Ext Int Ext Int Ext Ext Int SMED’s Conceptual Stages and Practical Techniques 1 Separate internal and external setup 2 Convert internal setup to external setup 3 Streamline all aspects of setup operations 1.- Check List 2.- Function Checks 3.- Improved transport of parts and tools 1.- Advance preparation of operating conditions 2.- Function standardization 3.- Intermediary jigs 1.- Parallel operations 2.- Functional clamps 3.- Eliminating adjustments 4.- Mechanization 1.- Improved storage and management of parts and tools
  22. 22. SET-UP Reduction Workshop SS MM EE DD 22 SSingleingle MMinuteinute EExchange ofxchange of DDieie Typical Set-Up Operation and % of Set-Up Time before SMED improvements Clamping & Removing Dies and Tools 5% Preparing Materials, dies, fixtures 30% Centering & Determining dimensions of tooling 15% Trial processing & adjustments 50%
  23. 23. SET-UP Reduction Workshop SS MM EE DD 23 SSingleingle MMinuteinute EExchange ofxchange of DDieie ACTION The winners Circle
  24. 24. SET-UP Reduction Workshop SS MM EE DD 24 ACTION • Why SMED • Terms and Concepts • Analyzing Set-Up Operations • Separate Internal and External • Checklists • Perform Function Checks • Improve Transport of Dies and Tools • Action
  25. 25. SET-UP Reduction Workshop SS MM EE DD 25 Observe with a video If there is no one on the screen = waste Observation & analysis method
  26. 26. SET-UP Reduction Workshop SS MM EE DD 26 Describe, Analyze & Improve • DESCRIBE our set-ups in a standard fashion • ANALYZE our set-ups • IMPROVE our set-ups
  27. 27. SET-UP Reduction Workshop SS MM EE DD 27 SET-UP ANALYSIS FORM Current time Improvement No Task/Operation Internal External Internal External Current total Improve total Internal: Operations that necessitate the stopping of the machine External: Operations not requiring the stopping of the machine Key terms: ASSEMBLE, DISMANTLE, USE, TRANSPORT (EMPTY), TAKE, TRANSPORT (FULL), PUT DOWN, FIND, CHOOSE, INSPECT, DEPLACE (REPOSITION), HOLD , WAIT, LOOK FOR. Proposed time Analysis form
  28. 28. SET-UP Reduction Workshop SS MM EE DD 28 SMED: Analysis Steps SMED Graph EXT. INT. EXT. INT. EXT. INT. Current Improved Ideal Time 1 2 3 4 5 6 7 1 2 3 4 6 7 8 8 1 3 4 6 7 1. Identify the set-up 2. List every step 3. Measure the time required for every step 4. Distinguish between internal and external steps 5. Plot the current graph set-up time 6. Convert as many internal steps to external steps 7. Reduce the internal steps time 8. Reduce the external steps time 9. Plot the improved graph set-up time 10. Define the ideal set-up 11. Plot the ideal graph and strive toward it. Analysis steps
  29. 29. SET-UP Reduction Workshop SS MM EE DD 29 Graph analysis Setup Time Bar Chart 25 22 9.5 8 3 0 5 10 15 20 25 30 1 2 3 4 5 Observation Number Time Goal
  30. 30. SET-UP Reduction Workshop SS MM EE DD 30 Press Control Panel 1 2 8 5 3 7 6 4 9 Die Rack Raw Mtl. Incoming Carbon Scrap A286 Scrap 19 11 12 13 14 15 16 17 18 10 21 20 single worker Spaghetti DiagramSpaghetti Diagram Raw Mtl. Return
  31. 31. PROCESS FLOW ANALYSIS CHART PROCESS: # Activities AC TIVITY TR AN SPO R TATIO N IN SPEC TIO N D ELAY FILE D EC ISIO ND O C U M EN T C O M PU TER W orking Tim e (H rs) Elapsed Tim e (H rs) D istance ELIM IN ATE C O M BIN E SEQ U EN C E TR AIN IN GIM PR O VE CHANGES CURRENT W orking Tim e (H rs) Elapsed Tim e (H rs) D istance PROPOSED PLAYER: Tasks
  32. 32. SET-UP Reduction Workshop SS MM EE DD 32 ACTION • Why SMED • Terms and Concepts • Analyzing Set-Up Operations • Separate Internal and External • Checklists • Perform Function Checks • Improve Transport of Dies and Tools • Action
  33. 33. SET-UP Reduction Workshop SS MM EE DD 33 3 Techniques to separate Internal and External Set-Up tasks. • Checklists • Perform Function Checks • Improve transport of Dies and Tools Stage 1Stage 1
  34. 34. SET-UP Reduction Workshop SS MM EE DD 34 Checklists Everything required to Set-Up and run. • Tools, specifications and workers required. • Proper values for operating conditions. • Correct Documents (work order, part prints, First Article forms, etc.) Stage 1Stage 1
  35. 35. SET-UP Reduction Workshop SS MM EE DD 35 Checklist ExampleChecklist Example Employees Required: 1 Set-Up Checklist Date: Equipment: Stamper Part #: K51086-4 Operation: 303 Name: Tools Required 3/4 inch Wrench 5/16 Hex Key 3/4 inch Wrench Parts Required Stamp# 562-1587 Lay Out# 909-3578 Standard Operating Procedures SOP 001 (changeover)
  36. 36. SET-UP Reduction Workshop SS MM EE DD 36 Function Checks • Tell you whether the parts (tools, dies, product, etc.) meet the specification and are in perfect working order. • Should be done well in advance of the Set-Up so repairs can be made if something is incorrect. Stage 1Stage 1
  37. 37. SET-UP Reduction Workshop SS MM EE DD 37 Improved Transport of Parts and Tools • Transport new parts and tools to the machine before it is shut down to do the Set-Up. • Put away old parts and tools after the new parts and tools are installed and running. • If machine is manually operated, may require coordination with another worker assigned the task of transporting. Stage 1Stage 1
  38. 38. SET-UP Reduction Workshop SS MM EE DD 38 Action To begin a set-up analysis • Identify every step • Characterize every step • currently internal or external • Suggest how to transform the internal steps to external ones
  39. 39. SET-UP Reduction Workshop SS MM EE DD 39 ACTION • Convert Internal to External • Checklists • Perform Function Checks • Improve Transport of Dies and Tools • Streamline all aspects of the Set-Up Operation • Improve storage of Tools, Dies, Jigs & Gauges • Improve Transportation of Tools and Parts • Implement Parallel Operations • Functional Clamps • Eliminate Adjustments • Mechanization • Action
  40. 40. SET-UP Reduction Workshop SS MM EE DD 40 2 Steps to converting Internal to External Set-Up • Analyze the true functions and purposes of each operation in the current internal Set-Up. • Find ways to convert these internal Set- Up steps to External. STAGE 2STAGE 2
  41. 41. SET-UP Reduction Workshop SS MM EE DD 41 3 techniques for converting Internal to External Set-Up • Advance preparation of Operating Conditions. • Function Standardization. • Intermediary Jigs. STAGE 2STAGE 2
  42. 42. SET-UP Reduction Workshop SS MM EE DD 42 • Get the necessary parts, tools and conditions ready before Internal Set-Up begins. Conditions like temperature, pressure or position of materials can often be prepared externally. Advance preparation of OperatingAdvance preparation of Operating Conditions.Conditions.
  43. 43. SET-UP Reduction Workshop SS MM EE DD 43 Prepare tools ahead of time
  44. 44. SET-UP Reduction Workshop SS MM EE DD 44 Tools, gauges, accessories, information Next kit Preceding kit machine kit 1 kit 2 kit 3 kit 4 kit 5 Kits distributor Reassemble (kits)
  45. 45. SET-UP Reduction Workshop SS MM EE DD 45 • Analyze each individual function in the Set-Up process and decide which functions can be standardized. • Look again at the functions and think about which can be made more efficient by replacing the fewest possible parts. The quickest way to replace something is to replace nothing at all - or as little as possible. Function StandardizationFunction Standardization
  46. 46. SET-UP Reduction Workshop SS MM EE DD 46 DIE BDIE A 20 Standardized Clamping Height Standardized Shut Height Standardized Clamping Function Function StandardizationFunction Standardization 7 7 6 6 Standardized Pass Line Height on Dies that run strip stock 10 10
  47. 47. SET-UP Reduction Workshop SS MM EE DD 47 Function StandardizationFunction Standardization Use Jigs to position Tools / Dies Die or Tool Top View of MachineMachine Jig attached to Machine Jig attached to Die / Tool
  48. 48. SET-UP Reduction Workshop SS MM EE DD 48 Function StandardizationFunction Standardization Die Cassette System Die Shoe Stays in Press Die cassettes are the only tools changed
  49. 49. SET-UP Reduction Workshop SS MM EE DD 49 Die Cassette System Function StandardizationFunction Standardization
  50. 50. SET-UP Reduction Workshop SS MM EE DD 50 Function StandardizationFunction Standardization Die Cassette System
  51. 51. SET-UP Reduction Workshop SS MM EE DD 51 • Used to change Internal Set-Up tasks into External. • Standardized plates or frames that can be removed from the machine. • Next job is Set-Up on the Intermediary Jig while current job is running. Intermediary JigsIntermediary Jigs
  52. 52. SET-UP Reduction Workshop SS MM EE DD 52 Tool or part A Tool or part B Positioning Jig Intermediary JigIntermediary Jig clamps Intermediary JigsIntermediary Jigs
  53. 53. SET-UP Reduction Workshop SS MM EE DD 53 ACTION • Convert Internal to External • Checklists • Perform Function Checks • Improve Transport of Dies and Tools • Streamline all aspects of the Set-Up Operation • Improve storage of Tools, Dies, Jigs & Gauges • Improve Transportation of Tools and Parts • Implement Parallel Operations • Functional Clamps • Eliminate Adjustments • Mechanization • Action
  54. 54. SET-UP Reduction Workshop SS MM EE DD 54 Streamline all aspects of the Set- Up Operation. • All remaining External Set-Up operations are improved. • All remaining Internal Set-Up operations are improved. • Examine each operation’s function and purpose one more time. STAGE 3STAGE 3
  55. 55. SET-UP Reduction Workshop SS MM EE DD 55 Improve storage of Tools, Dies, Jigs and Gauges. • Tools should be stored at or near point of use in an identified spot. • Dies should be labeled with die number and storage location. • Dies / Tools that are used most frequently should be stored nearest to point of use. Streamlining External Set-Up Stage ThreeStage Three
  56. 56. SET-UP Reduction Workshop SS MM EE DD 56 Decrease walking time. Stop searching. machine machine BEFORE AFTER Tools, gauges, accessories, information Streamlining External Set-Up Stage ThreeStage Three
  57. 57. SET-UP Reduction Workshop SS MM EE DD 57 01 Die# 25695 04 Die# 481614 02 Die# 35892 03 Die# 124653 01 02 0403 Streamlining External Set-Up Tool / Die Storage Example Stage ThreeStage Three
  58. 58. SET-UP Reduction Workshop SS MM EE DD 58 Improve transportation of Tools and Parts. • Make sure we are using the proper device to transport Tools and Parts. • If delays occur while waiting for a fork truck, consider getting a dedicated die cart. Streamlining External Set-Up Stage ThreeStage Three
  59. 59. SET-UP Reduction Workshop SS MM EE DD 59 • Implement Parallel Operations • Use Functional Clamps • Eliminate Adjustments • Mechanization Streamlining Internal Set-Up Stage ThreeStage Three
  60. 60. SET-UP Reduction Workshop SS MM EE DD 60 Implement Parallel Operations • One person Changeovers on large machines mean wasted time and movement. • Parallel Operations divide the Set-Up operations between two or more people. • When using Parallel Operations it is important to maintain safe operations. Stage ThreeStage Three Streamlining Internal Set-Up
  61. 61. SET-UP Reduction Workshop SS MM EE DD 61 Press Control Panel 1 2 8 5 3 7 6 4 9 Die Rack Raw Mtl. Incoming Carbon Scrap A286 Scrap 19 11 12 13 14 15 16 17 18 10 21 20 single worker Before Parallel OperationsBefore Parallel Operations Raw Mtl. Return
  62. 62. SET-UP Reduction Workshop SS MM EE DD 62 Press Control Panel 1 2 8 5 3 7 6 4 9 Die Rack Raw Mtl. Incoming Raw Mtl. Return Carbon Scrap A286 Scrap 11 10 1 2 3 4 5 6 78 9 10 worker 2worker 1 After Parallel OperationsAfter Parallel Operations
  63. 63. SET-UP Reduction Workshop SS MM EE DD 63 BOLTS • In the SMED System Bolts are the ENEMY • Bolts Get Lost, they fall under machines. • Bolts Get Mismatched, they aren’t always standardized, matching up the right nuts and bolts take time. • Bolts Take Too Long To Tighten, the releasing and fastening only happen on the first and last turns. Stage ThreeStage Three
  64. 64. SET-UP Reduction Workshop SS MM EE DD 64 Functional Clamps • A Functional Clamp is a device that holds objects in place with minimal effort. • Most Functional Clamps can stay attached to the machine so there is nothing to get lost or mismatched. • Functional Clamp systems include one- turn, one-motion and interlocking methods. Stage ThreeStage Three
  65. 65. SET-UP Reduction Workshop SS MM EE DD 65 One-Turn Methods Pear-Shaped Hole Method Stage ThreeStage Three
  66. 66. SET-UP Reduction Workshop SS MM EE DD 66 One-Turn Methods C-Shaped Washer Method Stage ThreeStage Three
  67. 67. SET-UP Reduction Workshop SS MM EE DD 67 One-Turn Methods Clamp Method Stage ThreeStage Three
  68. 68. SET-UP Reduction Workshop SS MM EE DD 68 One-Turn Methods U-Slot Method Stage ThreeStage Three
  69. 69. SET-UP Reduction Workshop SS MM EE DD 69 One-Turn Methods Split Thread Method Nut Bolt Stage ThreeStage Three
  70. 70. SET-UP Reduction Workshop SS MM EE DD 70 One-Motion Methods Spring Stops Spring Stage ThreeStage Three
  71. 71. SET-UP Reduction Workshop SS MM EE DD 71 One-Motion Methods Cam Clamp Work piece Machine Cam Stage ThreeStage Three
  72. 72. SET-UP Reduction Workshop SS MM EE DD 72 One-Motion Methods Magnet Method Machine Magnet Work Piece Stage ThreeStage Three
  73. 73. SET-UP Reduction Workshop SS MM EE DD 73 Interlocking Method Tool Holder Tool Holder Machine Machine Stage ThreeStage Three
  74. 74. SET-UP Reduction Workshop SS MM EE DD 74 Eliminating Adjustments • Trial Runs and Adjustments can account for 50% of the time in a traditional Set-Up. • Three practical techniques for eliminating adjustments: • Use numerical scales and make standardized settings. • Make imaginary center lines and reference planes visible. • Use the Least Common Multiple system. Stage ThreeStage Three
  75. 75. SET-UP Reduction Workshop SS MM EE DD 75 Eliminating Adjustments Cut off to 4 inches, how to Set-Up ?? Shear operation Work Piece B l a d e Stage ThreeStage Three
  76. 76. SET-UP Reduction Workshop SS MM EE DD 76 Eliminating Adjustments Fixed Numerical Settings Shear operation Work Piece 12345 B l a d e Stage ThreeStage Three
  77. 77. SET-UP Reduction Workshop SS MM EE DD 77 Eliminating Adjustments Cutting Tool Center Line, (Invisible)Work Piece Lathe Visible Center Lines and Reference Planes How to set the Tool to the Center Line?? Stage ThreeStage Three
  78. 78. SET-UP Reduction Workshop SS MM EE DD 78 Work Piece Lathe Cutting Tool Center Line, (Invisible) Visible Center Lines and Reference Planes Mark Center Line on Housing Stage ThreeStage Three
  79. 79. SET-UP Reduction Workshop SS MM EE DD 79 Eliminating Adjustments Least Common Multiple System Limit Switch Material 4 different shaft lengths required, 5 ft., 7.2 ft., 8.4 ft. and 10 ft. Stage ThreeStage Three
  80. 80. SET-UP Reduction Workshop SS MM EE DD 80 Eliminating Adjustments Least Common Multiple System 1 2 3 4 Limit Switch Control Panel ON OFF ON OFF ON OFF ON OFF 5 7.2 8.4 10 Length Material Stage ThreeStage Three
  81. 81. SET-UP Reduction Workshop SS MM EE DD 81 RAM Upper Die Lower Die Least Common Multiple System Limit Switch Stage ThreeStage Three
  82. 82. SET-UP Reduction Workshop SS MM EE DD 82 RAM Upper Die -5 -6 -4 Lower Die Least Common Multiple System Limit Switch Rotary Stopper Stage ThreeStage Three
  83. 83. SET-UP Reduction Workshop SS MM EE DD 83 Mechanization • Should be considered only after every attempt has been made to streamline setups using the other techniques discussed. Stage ThreeStage Three
  84. 84. SET-UP Reduction Workshop SS MM EE DD 84 Synchronize Stages with GoalsSynchronize Stages with Goals Original Setup Stage one Stage Two Stage Three 50% 75% 90%
  85. 85. SET-UP Reduction Workshop SS MM EE DD 85 Action • Convert Internal Set-Up to External Set-Up • Streamline all aspects of the Set-Up Operation • Prepare for Wednesday’s Presentation • Prepare for Friday’s Final Presentation
  86. 86. SET-UP Reduction Workshop SS MM EE DD 86 Thursday’s Presentation • Set-Up Analysis Form • Set-Up Graph Analysis Form • Spaghetti Diagram (current condition) • Process Flow Analysis Chart • Stage 1 and 2 Improvements SSingleingle MMinuteinute EExchange ofxchange of DDieie
  87. 87. SET-UP Reduction Workshop SS MM EE DD 87 Final Presentation • Set-Up Analysis Form • Set-Up Graph Analysis Form • Spaghetti Diagram (before and after) • Process Flow Analysis Chart • Stage 1, 2 and 3 Improvements • Pictures SSingleingle MMinuteinute EExchange ofxchange of DDieie

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