1. A “Set-Up” is an individual event that has historically been seen as a
necessary evil in order to produce parts.
Traditional Thought Process of the “Set-Up”
Modern Thought Process of the “Set-Up”
A “Set-Up” is a team event that has allows a business to
be more competitive by using the manufacturing team to
reducing costs, inventory levels and scrap.
SMED Exercise for 45 Ton Presses

2. Manufacturing is a team effort
Being organized and prepared wins the race
Using the example of NASCAR we reasoned that preparation and teamwork
are essential to the success of the team
With this in mind the following recommendations are made

3. By using averages we were able to
determine the larger segments that
were common and needed to be
addressed, in order to develop a
standard to work to most times
The goal being to move as much time
from the internal time to the external
time, taking advantage of completing
set-up tasks while production is being
ran
Task 1 2 3 Average
QC 25.4 14.09 22.3 20.60
Remove material 11 0 5.5 8.25
Bolt die down 9.1 9.1 6.5 8.23
Hunt chute 1.4 5.17 10.2 5.59
Lace up 6.9 2.15 0 4.53
Load new material 5.3 2.41 4.3 4.00
Unbolt and remove die 5.7 1.2 4.07 3.66
Transport die to press 2.9 2.48 4.3 3.23
Set feed hgt 1.4 2.3 1 1.57
Press Problem 1.5 0 0 1.50
Move air line 1.1 0 0 1.10
Place die on Bolster 1.2 1 1 1.07
Get tools 1 0 0 1.00
Get Paperwork 0.2 1.55 0 0.88
74.1 41.45 59.17 58.24
37.64
Average time (all internal Time) 37.64
Estimated time to tranfer to external 17.77
Time internal 19.87
Internal Time 37.64
External Time 0
Time internal 19.87
Estimated time to tranfer to external 17.77
Base line Internal 37.64
Potential Internal 19.87
Baseline External 0
Potential Internal 17.77
Net Adjusted time (no QC)

4. Set-Up
time too long
Potential Root Causes for Long Set-Up Times
MANMACHINE
METHOD MATERIAL
No slots have
to use bolts
Tools not ready
Die not staged
Paper work not
at press
Material not
stagedSet feed with
calipers
Payoff not easy to
remove material
No standardization
QC delays
One man show
Not available
Lift not available
Hit Changes
No organization

5. No. Internal External
1 Inspection time x
2 Bolt Die down x Die not standard Standardize / slot dies and bolster
3 Hunt/Install chute x Chutes not organized Store with die or in die location
4 Lace Up / Set feed x Method of calipers Use progression bar
5 Load New Material x Wait for press to stop Stage ready to go
6 Unbolt and remove die x NA
7 Transport die to press x Die not available Stage ready to go
8 Set Feed Hgt x Die not standard Standize heights
9 Press Problem x Repaired Repaired
10 Move air line x Part specific
11 Place die on bolster x NA
12 Get Tools x NA
13 Get Paperwork x Location of paper work Paperwork staged at press or w material
14
15
16
17
18
19
20 Denotes recommended changes to reduce time
Task Type
Constraint Potential Correction
Set-Up Reduction Review : Time and Task Anaylsis , Constraint Identification, Constraint ResolutionPress Number 45 Ton
Part Number Average of 3 set-ups
Define individual task
Time for task completion
Total
20.6
8.25
5.59
4.53
4
3.66
3.23
1.57
1.5
1.1
1.07
1
1

6. Preparation Makes a Difference
Traditional – wait until production
stops, gather and go
Proposed – stage , team effort

7. Current Method Proposed Changes
Locate and install shank
adaptor
Each die should be standard
and have in place
Payoff difficult to band and
remove material
Add ½ round stock (minimum
height) to permit passing of
band stock
Bolt die in as best as possible
Hunt and find parallels
Mount parallels to each die
and have slots in each, slot
bolster never hunt clamps
again, 2 bolts vs. 4 bolts
Set feed with calipers Avoid variation-make
individual progression bars

8. Traditional Methods Proposed Methods
Band material end of run
Remove material from payoff
Retrieve next material
Unload on payoff
Cut bands
Stock Material
Stage next run material on
payoff, bands cut and
exchange payoffs while die
being set. Material is secured
afterwards and restocked
Remove die and restock on
shelve
Retrieve die and place on
bolster
Stage die on rolling table so
that when die is removed,
next die is on same table and
stored after setup is complete
Hunt and/or modify chutes
that are laying around
Identify chutes and store with
die or in die location as
needed

9. Summary of Team
Efforts and Recommendations
The original goal of a 25% reduction with little to no cost was not only
achieved but surpassed – by moving tasks to external (staging) we were
able to move at least 38% of the efforts which will directly reduce cost
We feel that by following the recommendations that the set – up of 45 ton
presses can be further reduced to bring the total under 50% and that the
potential to be under 10 minutes does exist

10. Summary of Team
Efforts and Recommendations
The original goal of a 25% reduction with little to no cost was not only
achieved but surpassed – by moving tasks to external (staging) we were
able to move at least 38% of the efforts which will directly reduce cost
We feel that by following the recommendations that the set – up of 45 ton
presses can be further reduced to bring the total under 50% and that the
potential to be under 10 minutes does exist