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Development of a TeachingTool for Setup Time Reduction

using Lean PrinciplesPresented by

Amey Vidvans

IE 550-Manufacturing Systems

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Reduced inventory due to single piece o! Reduction in cycle times Room for continuous improvement

Reduction in variability

"le#ibility of product mi#

 

Why reduce setup time?

$e % $o&' ts

&(cs&)*s' (*s-+,)*s

&,

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ttp.))!!!/slidesare/net)anandsubramaniam)set-up-reduction

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Identify elements(Internal and E#ternal, and!aste

Incorporate Automation

Eliminate adustment Eliminate use of tools Incorporate modular design Incorporate 1uic2 action mecanisms

Ways to reduce setup time

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 3e Seven 4astes of ean Manufacturing are6 3ransport Inventory

Motion 4aiting 7ver-Processing 7verproduction 8efects

Wastes

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Identifying wastes in the oldsetup

Activity Analysis

Removing and boltingon ne! die

9se of non standardbolting: loo2ing for tools

Installing ne! punc Adustment oforientation and bolting

"eeder Adusting according tone! incoming strip!idt: scre!ing

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Incorporation of changes

Punc adustment andbolting eliminated

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oss of !asers and need for

!renc eliminated

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Adustment and need for scre!driver eliminated

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1uic2 cangeover

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Eliminates 3ools: free to use bot ands insetup

Standardised modular design

1uic2 action clamping and bolting "ast cangeover Eliminates feeder adustment

Salient features

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Activity Time taen

Removing nuts and die &m+5s';0s%&m55s

"i#ing ne! die and bolt +

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Activity Time taen

Removing die and fasteners &+s';;s%+m5s

"i#ing die and fasteners &0s'+5s%?5s

Punc removal and installation &s'&s%;s

"eeder adust(remove and @#, +

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 3e time study conducted on te variouselements reveals tat te average timereduces by =? by incorporating eanPrinciples/

 3ere is al!ays room for continuousimprovement/

&onclusion

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Than you