Initial observations of fitting setup data found approximately 25 setups annually on fitting machines, with an average setup time of over 300 minutes and a cost of $1.59 per minute. Through efforts to standardize fittings and reduce setup times, the team reduced the average setup time to 136 minutes, realizing over $11,000 in savings from the reduced time. A design consolidation provided an additional $5,000 in hard savings, while freeing up capacity and enabling faster response times. Inventory was also reduced by 38% through introducing IPK to reduce work-in-process levels.

1. FITTING SETUP REDUCTION

2. FITTING SETUP REDUCTION

3. INITIAL OBSERVATIONS
• Looking at data, we found the following:
• ~25 setups annual on Fitting Machines
• Average setup was over 300 minutes
• $1.59/minute = Multi-Spindle cost

4. Standardizing The Fittings:
Design Update

5. Current State – Two Blanks

6. CURRENT STATE –
AUTOLOADER LATE MODEL CUSTOMIZATION
(THREADING)

7. Introduction of IPK to Reduce WIP Inventory

8. Facts and Figures
•With the efforts of the Setup Reduction team, we reduced current setup time down
to 136 minutes and expect to further reduce the setup time down to approach
SMED.
• After the Kaizen Event we realized over $11,000 savings
• The design consolidation results in an additional $5000 hard savings
• Additional capacity
• Faster response time

9. Facts and Figures
•In addition, there are other savings and benefits that have not been calculated.
• Reduced WIP/Inventory approx. 38% (3900 to 2400 pieces)
• Reduced tooling costs through reduced tool inventory
• Freed up capacity