10 Essential Steps in Reducing Setup Time
Plus 2 Quotes and 1 Image to kindle your thoughts
1 Article of the week:
Recently, We are working with a spring manufacturing company. They have a huge Inventory of parts (both FG and WIP), but still not able to meet the demand.
We did a ABC analysis of the items and found out that only 70 items contribute to 80% of the revenue (out of 500+ items). When we analysed the stock positions, we found that B and C category items are in huge stock.
Later we found that, since the setup time is high, the employees finish the entire coil and then only moving to the next product. This means, even if there is less load for C category items, they are producing in very high numbers.
The fundamental reason is High Setup time and people try to avoid it. In this case the setup time is more than 5 hours, which we are planning to bring it to less than 1 hour.
Here are some of the essential steps to reduce Setup Time:
1. Standardize Processes: Use clear, documented procedures for all setups.
2. Implement 5S methodology: removal of Non-moving items from workplace, visual identification to be followed.
3. Quick-Change Tools: Use tools that are easy and quick to switch out.
4. Pre-Setup Activities: Get all tools and materials ready before starting the setup.
5. Clear Communication: Provide clear instructions and use real-time communication tools.
6. Visual Aids: Use diagrams, checklists, and labels to guide the setup.
7. Optimize Tool Storage: Arrange tools for easy access and quick retrieval.
8. Training: Train and cross-train staff on efficient setup techniques.
9. Regular Maintenance: Keep all equipment in good working condition to avoid delays.
10. Continuous Improvement: Collect data, review, and improve setup processes regularly.
I have explained the Step-By-Step approach to reduce the changeover time in the following video.
I hope this post is useful. Please share your thoughts in comments.
2 Quotes for the Week:
“Without standards, there can be no improvement.” — Taiichi Ohno
“All we are doing is looking at the time line, from the moment the customer gives us an order to the point when we collect the cash. And we are reducing the time line by reducing the non-value adding wastes.” - Taiichi Ohno
1 Image for the Week:
