Easy and Simple Way to reduce 50% of Setup Time.
+ 1 Video comparing Indian Steel Companies + 1 Quiz to kindle your thoughts
1 Article for the Week:
Easy and Simple Way to Reduce your Changeover time by 50%
While talking about Changeover time reduction, many Managers and professionals immediately ask for Infrastructure / high-tech tools. With "0" Cost, we can reduce the setup time by 50% (in most cases).
How to do it?
Classify the activities performed during setup into Internal and External Activities.
1. Internal Activities need to be performed only when the machine is stopped (activities inside the machine). E.g. Removing the Punch and Die, setting the new mould in the machine.
2. External Activities can be performed outside the machine, when it is running. E.g. Arranging the new punch and die, Getting the tools, preheating the Raw materials, putting back the old moulds, etc.
In many instances, people perform the External Activities after stopping the machine. i.e. they will transport the new punch and die after stopping the machine, search for tools, minor rework on the jigs and fixtures, etc.
In our experience, we can easily eliminate 50% of the setup, by completing all the external activities when the machine is running.
Still having doubts, go and check it in your shopfloor yourself.
Found this useful? Please share it with your Production Team and help them reduce the Changeover time.
1 Video for the week:
We had done a Benchmarking Study comparing the Operations Performance of Steel Companies in India (Tata Steel, JSW and SAIL).
Here are the findings.
1. Tata is better in Gross Margins %, has a better cost control. One Exceptional item dragged their Net Profit.
2. JSW has the lowest Employee Cost%, whereas SAIL has the lowest Finance Costs.
3. SAIL has the highest Inventory Cost%, their Inventory Turnover is around 3.8 whereas Tata and JSW has more Inventory Turnover (around 6.6)
Watch the video to know more…
1 Quiz for the Week:
What is the visual tool generally used in machines to indicate the running / breakdown of machines?
Kaizen
Kanban
Andon lights
Value Stream Mapping
Share your answer in “Reply” and get featured in the next week’s newsletter circulated to more than 5500 professionals.
Congratulations to Mr. Shibi Chandraguru for sharing the correct answer.
That's all for now, friends! Thanks for reading, and we'll catch you in the next one. Cheers!
Ananth Palaniappan