05+Setup_Operations

05+Setup_Operations - SETUP OPERATIONS SETUP a A setup...

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Unformatted text preview: SETUP OPERATIONS SETUP a A setup operation (or simply setup) setup is the preparation or after adjustment that is performed once before and one after each lot is processed. one Basic Steps in a Setup Operation Operation 1.Preparation, After Process Preparation, Adjustments, Checking of Materials and Tools and 2.Mounting and removing blades, Mounting Tools, and Parts Tools, 3.Measurements, Settings and Measurements, Calibrations Calibrations 4.Trial Runs and Adjustments SETUP The Root of Many Problems The a a a a a a a a a Long delivery times Poor quality Higher WIP Longer cycle times Obsolescence Larger raw material stores Larger finished goods stores Make to stock Lost competition with lean competitors Setup time > 0 ⇒ batch size > 1 size a The famous EOQ formula indicates The this this a 2•S • D 2•S h Q* = a Where, S is setup cost, D is demand Where, rate, and h is unit inventory holding Effects of Setup Reduction Effects The total cost of building batches in The anticipation of demand is given by anticipation TC = S(D/Q) + H(Q/2) Where, S=setup cost, H= holding cost, Where, Q=batch size. Q=batch The graph of TC and its two The components are given below. components Effects of Setup Reduction Effects Total cost = AD/Q + hQ/2 Holding cost =hQ/2 Setup cost = AD/Q Q* Effects of Setup Reduction Effects Annual Cost If Snew < Sold Total cost = SD/Q + hQ/2 Holding cost =hQ/2 Setup cost = SD/Q Q*new Q*old Q Components of Setup Time Components External vs. Internal a Internal Setup: This part of the setup This operation can only be done when the machine is shut down. For example, a new die can only be attached to a press when the press is stopped. press Components of Setup Time Components External vs. Internal a External Setup: This part of the setup This operation can be done while the machine is still running. For example, bolts to attach to the die can be assembled and sorted while the press is operating. the Components of Setup Time Components Separating Internal and External Internal Setup Setup a a a Certain tasks can be done before machines are Certain stopped for changeover. These include lining up the right people, preparing parts and tools, making repairs, and bringing parts and tools closer to the equipment. closer It is surprising however, that often these tasks It are done after the machine has been stopped instead of while it is still running the previous lot. instead A checklist that lists everything required to set checklist up and run the next operation will minimize those external setup elements that are performed as internal elements. internal Components of Setup Time Components Separating Internal and External Separating Internal Setup Setup a Checklist: • Tools, specifications, and workers Tools, required required • Proper values for operating conditions Proper such as temperature pressure, current, and feed rate and • Correct measurements and dimension Correct required for each operation required • Function checks before the setup Components of Setup Time Components Separating Internal and External Separating Internal Setup Setup a Improve Improve the transport of parts and tools. Make sure that during this transport the machine is still running. running. Components of Setup Time Components Converting Internal Setup to External Internal Setup Setup 1.Look closely at each individual Look function in your setup process and decide which functions, if any, can be standardized. be 2.Look again at the functions and think Look about which can be made more efficient by replacing the fewest possible parts. possible Components of Setup Time Components Improving the Internal setup The quickest way to replace The something, of course, is to replace nothing at all - or as little as possible. Components of Setup Time Components Improving the Internal setup Function standardization – – – – – – – – – – Standardize clamping operations Use jigs to center dies Use Use die cassette systems Use intermediary jigs Implement parallel operations Use functional clamps Eliminate adjustments Fix numerical settings Make centerlines and reference planes visible Use limit switches, sensors and other warning Use devices devices Single Minute Exchange of Dies Dies SMED a The philosophy of SMED was borne The in 1950 by Shigeo Shingo while he was conducting efficiency improvement survey at Toyo Kogyo’s Mazda Plant in Hiroshima. Kogyo’s Single Minute Exchange of Dies Dies SMED a Shingo proposed the following Shingo conceptual stages for SMED: conceptual Preliminary Stage: Internal and external Setup conditions are not distinguished Setup Stage 1: Separating internal and external setup external Stage 2: Converting Internal to external setup setup Stage 3: Streamlining all aspects of the Single Minute Exchange of Dies Dies Applying SMED to Internal Applying Operations a a Implement parallel operations Use functional clamps • • • • • • • • One turn attachments Pear-shaped holes for clamping U-shaped washers for clamping Split thread screws for one turn operations U-slots for attachment Clamping instead of screwing One motion clamping devices Interlocking devices Single Minute Exchange of Dies Dies Applying SMED to Internal Operations a Elimination of adjustments • Fixing numerical settings • Make centerlines and reference planes clearly Make visible visible • Use sensors and limit switches • Use mechanization (only after exhausting Use other means) in streamlining the setup. other • Use the energy provided by the machine to Use speed up setup operations speed SMED Example SMED SMED Example SMED SMED Example SMED SMED Example SMED SMED Example SMED SMED Example SMED SMED Example SMED SMED Example SMED SMED Example SMED SMED Example SMED SMED Example SMED SMED Example SMED SMED Example SMED SMED Example SMED SMED Example SMED SMED Example SMED SMED Example SMED ...
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This note was uploaded on 10/25/2011 for the course EIN 4401 taught by Professor Staff during the Fall '08 term at University of Florida.

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