Analyze Improve Define Measure Control Improve L EAN S IX S IGMA L EAN S IX S IGMA Ensuring Value...
Transcript of Analyze Improve Define Measure Control Improve L EAN S IX S IGMA L EAN S IX S IGMA Ensuring Value...
AnalyzeAnalyze ImproveImproveDefineDefine MeasureMeasure ControlControl
Imp
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Imp
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LEANSIX SIGMA
LEANSIX SIGMA
Ensuring Value(Part 2)
Quick Changeover / Set-up Reduction
AnalyzeAnalyze ImproveImproveDefineDefine MeasureMeasure ControlControl
Imp
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Imp
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LEANSIX SIGMA
LEANSIX SIGMA
Set-Up Reduction Set-Up Reduction Introduction
Effect of Set-Up Reduction
The Four-Step Method
Implementing Set-Up Improvements
RD010402
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Total Cost is Key (review) In Lean Manufacturing, we focus on reducing waste
in our processes, by focusing on: Productivity (pieces per hour; cycle time; schedule
attainment) Quality (scrap and rework; fit with customer needs) Downtime (equipment uptime; availability of qualified
personnel) Speed (on-time delivery; lead-time; order-to-delivery) Cost (to produce each piece; overtime; expediting)
The Seven Deadly Wastes• Over-producing• Waiting• Over-processing• (Too Much) Inventory• (Unnecessary) Motion• Defects or Rework• (Excessive) Transportation and Materials Handling• Plus One More: Underutilized (Human) Resources
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Cycle Time Barriers (review)
Set-up Events are one of the key barriers to fast cycle times.
Input Output
Cycle Time
Operation 1
Operation 2
Operation 3
Operation 4
Multi-Step Process
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Production
Downtime Ramp-up time
Job# 1
Job# 2
What Is Set-Up Reduction?Set-Up Reduction is a process in which the time and
effort for equipment changeover is reduced to an absolute minimum without adversely affecting quality.
Two components of set-up reduction that must be addressed are: Machine down time or set-up/changeover time Machine ramp-up time (i.e., making adjustments to meet
specs)Total Time Lost to S/U and
C/O
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Set-Up Time Defined
50%
30%
5%
15%
Last GoodProduct of Run
First GoodProduct(s) of Run
Preparation
Trial Runs
Adjustments
Actual S/U
A B
Set-Up Time is the length of time between the last good product of a production run to the first good product(s) of the next
production run
Set-Up Time
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Components in the Set-Up Process Preparation:
Obtain work order and instructions
Gather and return tools
Retrieve and return change parts
Clean machine Check materials Clean work areas
Set-Up: Change machine /
equipment hardware Mount and remove
dies, tools, blades, etc.
Adjustments: Measure / calibrate Center dies, tools,
blades, etc. Modify settings
Trial Runs: Adjust after test or 1st
piece product is made Inspect / measure test
piece or 1st piece
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ImproveAdvantages of Rapid Set-Up Over Typical Set-Up
Cut scrap and rework risk by 50+%
Cut inventory investment by 50+%
Able to introduce quality improvements at twice the rate (more cycles of learning)
Able to change the schedule twice as often to meet changing customer demands
Able to introduce design changes at twice the rate
Increase available floor space
,
,
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Four-Step Set-Up Reduction Method 1. Document Set-Up and then Separate Events into
Internal and External
2. Convert Internal Events to External Events
3. Streamline Internal Set-Up
4. Eliminate Adjustments
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Step 1 of 4
STEP 1Document the set-up and
separate events into internal or external
STEP 3Streamline internal
events(Simplify, Reduce,
Eliminate)
STEP 2Convert Internal
to External events
STEP 4Eliminate
adjustments internal to the set-
up
Step 1 is done first to attain benefits quickly
D, MD, M
A, IA, I II I, CI, C
xxxx“Corresponding” DMAIC phase for a stand-alone Set-Up Reduction project
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ImproveStep 1: Goal of Step 1
Goal: Document the set-up and separate into internal and external events: Internal Set-Up is an event that must be performed while
the equipment is down (not running or producing parts). Exchanging dies/fixtures in the machine
External Set-Up is an event that may be performed while the equipment is producing parts. Retrieving drawings, tools, hardware and parts Loading programs
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Physical Flow (review) Physical Flow represents the path of movement a
product family follows through a facility. The flow of the material (or a worker) is traced though the facility’s layout, showing the path and distance traveled while completing a task.Effects of Poor Physical Flow
• Long process cycle times• Excess materials handling or wait times• Damage to goods in-transit• Increased chance for injuries• Poor visibility to actual production
Typical Causes of Poor Physical Flow• Lack of materials handling equipment• Long distances between work stations• Large loads, batches or transfer sizes• Un-ergonomic placement of equipment• Poor process design or task order
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ImproveStep 1A: Area Layout Diagram (a.k.a. Spaghetti Diagram)
Document relative position of cabinets, tools, dies/fixtures, hardware, etc., in relation to the set-up activities
Record the movements of the operators/set-up personnel throughout the set-up activities
Track each foot traffic movement of key operators/set-up personnel to determine the total distance traveled during the operation Key in gaining buy-in (especially from the operators) to the
improvement suggestions
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ImproveStep 1A:Creating and Using the Area Layout
PunchPress#1465
Tool Carousel
Controls
Tool/Die & Fixture Room
Hardware Cage
ProductionControl
QualityControl
Hand ToolCabinet
Note: To enhance area layout readability, consider numbering each traffic line and / or use multiple area layout pages
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ImproveStep 1A:Area Layout (Example)
Does this appear efficient?
This set-up could probably be streamlined with better storage and location of needed items!
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ImproveStep 1A & 1B:Set-Up Documentation Worksheet
ITEM # _____________________________
See copy in Excel format within Appendix A
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Step 2 of 4
STEP 1Document the set-up and
separate events into internal or external
STEP 3Streamline internal
events(Simplify, Reduce,
Eliminate)
STEP 2Convert Internal
to External events
STEP 4Eliminate
adjustments internal to the set-
up
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Goal: Convert internal set-up events to external events: Re-examine internal events from Step 1 and verify they
are actually internal Convert any internal set-up events to external set-up
events using focused, engineered methods Change set-up procedures to reflect only internal activities Develop external activity procedures Use Brainstorming tools abundantly to gather and build
good ideas
Step 2: Goal of Step 2
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ImproveStep 2: Improvements Worksheet
The Improvements Worksheet is used to document all improvements to the set-up.
The worksheet is used to develop action plans (Continuous Improvement ‘To-Do’ List) and work orders that will initiate improvement implementation.
The reduction in set-up time is calculated on this sheet as improvements are implemented over time.
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ImproveStep 2: Improvements Worksheet (Example)
See copy in Excel format within Appendix A
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ImproveStep 2:Organize for Set-Up
Fact: Vast amounts of set-up time are lost due to searching for set-up hardware and set-up information. Set-Up Hardware:
Tools Fixtures Nuts and Bolts Clamping Devices Measuring Devices
Set-Up Information: Data (Tool and Machine Settings) Procedures Drawings
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ImproveStep 2:Organizing Set-Up Hardware
Set-Up hardware should be organized by either specific set-ups or by specific hardware or workstation.
Set hardware should be stored near the workstation. The storage locations should be labeled as to what set-
up or component is stored at that location. The fixtures and tools should be organized to easily
determine if components are missing prior to set-up (shadow-boards).
Set-Up data for machine settings, tooling settings and shim sizes should be placed on designated charts and stored near the workstation.
Detailed set-up procedures should be stored near the workstation.
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Time Action Parts89 Setup A101112 Setup B13
Part #432543Press # P-10 Review Check TableDie 274 Functional ChecksDie Location Shelf 4 Retrieve Change Parts
CRESCENTWRENCH
SCREWDRIVER
ALLENWRENCH
Step 2:Applications of Step 2
Checklists
Check Tables or Shadow-boards
Battle Plans
Functional Checks
Improving Transportation
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ImproveStep 2:Checklists
Checklist of parts and steps required in set-up Names of Tools Specifications Identification of Change
Parts (nozzles, pipes, hoses, etc.)
Settings (temperature, pressure, location, etc.)
Numeric Values for Measurements
2mm 4mm 5mm 6mm 14mm3/32 3/16 1/4 5/1624mm 27mm1 1-3/16 1-9/16 Adjustable wrenchChannel Lock Loc-Line Needle Nose
T-6 T-8
Large and Small
Part Description
Setup Tool List
Wrenches
Torx Wrenches
Cheater Bar
Soft face Hammer
Pliers
Ratchet with 14mm allen wrench
Flat head screwdriver
Part No.
Common Tools
Shim for workshift
Allen Wrench
Tap/Drill
Boring Bar
4 Flute End Mill
2 Flute End Mill
Specific Tools
File
Collet
Bore micrometer
O. D. micrometer
Thru Bore ref. gage
Key Way Go/No go
Bore Go/No go
Spade Drill & insert
Carbide Drill
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ImproveStep 2:Checklist (Example)
Press #: P-10
Die #: 274
Die Location: Shelf 4
Platen #: 42
Platen Location: Shelf 5
Tools: Die Cart, 1/4” and 1/8” Allen Wrench, Screwdriver, 1/4” Open-Ended Wrench
Settings: Ram 12.50
External Events Review check table Retrieve change parts Tools clean and in working
order Change parts clean and in
working order Functional checks completed
Part #: 432543
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ImproveStep 2:Check Table or Shadow-Boards
Provides "quick check" for tools. Tools are placed over drawings or outlines drawn on check
table or shadow-board. Missing tools are easily identified. Tools should be retrieved during external set-up time.
CRESCENTWRENCH
SCREWDRIVER
ALLENWRENCH
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ImproveStep 2:Battle Plans
Developed daily
Everyone involved in set-up and operation must know battle plan
TIME ACTION PARTS NOTES 8:00 AM 8:30 AM SETUP 031476 TEAM 1
9:00 AM 9:30 AM
10:00 AM SETUP 413222 TEAM 1 10:30 AM 11:00 AM 11:30 AM 12:00 PM 12:30 PM 1:00 PM 1:30 PM 2:00 PM 2:30 PM 3:00 PM 3:30 PM 4:00 PM SETUP 192413 TEAM 2 4:30 PM 5:00 PM
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ImproveStep 2:Functional Checks/Improving Transportation
Functional Checks Used in conjunction with checklist and check table
to determine if all set-up parts, tools, etc. are in perfect working order
Must be performed externally
Improving Transportation of Change Parts All transportation of change parts must be
performed externally Make use of a set-up tool cart, pail, tray or belt
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ImproveStep 2:Die Retrieval for Punch Press
OLD - 35 min
Continue set-up
Stop press - begin internal set-up
Remove die from press
Transport die to storage area
Retrieve new die from storage area
Transport die to press
Place die on press
35 m
in
Replace old die to storage
Retrieve new die from storage area
Continue set-up
Replace new die on press
Remove die from press
Stop press - begin internal set-up
Exte
rnal 11 m
in
NEW - 11 min
External events for the next run are to be performed while the prior part is being run.
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Step 3 of 4
STEP 1Document the set-up and
separate events into internal or external
STEP 3Streamline internal
events(Simplify, Reduce,
Eliminate)
STEP 2Convert Internal
to External events
STEP 4Eliminate
adjustments internal to the set-
up
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Goals of Step 3 Goal: Streamline internal set-up by streamlining
the internal set-up steps by:
Simplifying Movement
Reducing Movement
Eliminating Movement
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ImproveStep 3:Applications to Streamline Internal Set-Up
Reduce / eliminate need for hand tools
Reduce / eliminate nuts and bolts, hex nuts, etc.
Replace with quick fastening / releasing devices:
Single-motion securing
U-slot method
Pear-shaped hole method
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ImproveStep 3: Securing Method Exercise
Before: Traditional Securing Method 4 bolts per die 12 turns per bolt to secure
4 bolts/die x 12 turns/bolt = 48 turns/die 0.05 min/turn x 48 turns/die = 2.4 min/die 2.4 minutes to remove + 2.4 minutes to secure
4.8 minutes
4.8 minutes
Bolt with 12 Threads
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ImproveStep 3: Securing a Die, Pear Shaped Hole Method
After: Pear-Shaped Hole 4 bolts per die 1 turn per bolt to secure 1 turn per bolt to remove
4 bolts/die x 1 turn/bolt = 4 turns/die 0.05 min/turn x 4 turns/die = 0.2 min/die 0.2 min to remove + 0.2 min to secure
0.4 minutes0.4 minutes
Bolt with 12 Threads BUT only one turn to secure!
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ImproveStep 3:Securing a Die Comparison
Traditional = 4.8 Minutes
Pear-Shaped Hole = 0.4 Minutes
Internal Set-Up Time: Streamlined by 4.4 minutes Reduced by 92%
Internal Set-Up Time: Streamlined by 4.4 minutes Reduced by 92%
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ImproveStep 3:Nut & Bolt Improvement Methods
Reduce NumberReduce Numberof Screwsof Screws
U-Slot MethodU-Slot Method
ClampsClamps
Snap MethodSnap Method MagnetsMagnets
Pear Shaped Pear Shaped Hole MethodHole Method
Single Motion Single Motion ConnectionsConnections Use of CamsUse of Cams Toggle ClampsToggle Clamps
One-Turn One-Turn MethodMethod
Use Only 1 Type/ Use Only 1 Type/ Size of FastenerSize of Fastener
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ImproveStep 3:One-Turn Procedures
Eliminate lost nuts, bolts, different-size nuts and bolts
8 bolts to be removed 0 bolts removed8 half-turns to loosen
NEW – 1.6 min
OLD – 18 min
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Improve
Step 4 of 4
STEP 1Document the set-up and
separate events into internal or external
STEP 3Streamline internal
events(Simplify, Reduce,
Eliminate)
STEP 2Convert Internal
to External events
STEP 4Eliminate
adjustments internal to the set-
up
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ImproveStep 4:Goal of Step 4
Goal: Eliminating Adjustments The elimination of adjustments and trial runs by turning
intuition and guessing into fact and settings. Elimination means elimination – not reduction – in the
time required to perform adjustments.
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ImproveStep 4:Test Runs Are Typically 50% of Set-Up Time
Test Runs 50%
Test Runs 50%
Preparation30%
Preparation30%
Set-Up5%
Set-Up5%
Measurementsand Settings
15%
Measurementsand Settings
15%
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ImproveStep 4: Adjustments and Test Runs
Adjustments and test runs are normally due to: Inaccurate Centering Inaccurate Settings Inaccurate Dimensioning Inaccurate or Inadequate Measuring Poor Documentation
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ImproveStep 4: Eliminating Adjustments
Abandon reliance on intuition for settings
Settings as a result of intuition are inexact, are rarely replicable, and do not provide the required precision as constant value settings
Convert intuition to FACT
As long as settings are made based on intuition, there is no way to avoid adjustments and test runs
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ImproveStep 4: Pin and Place Method on Conveyor Rails
Before After
34 Minutes 8 Minutes
Screws
Slide & AdjustSlide & Adjust SetRail Fixed
Pins
One fixed side plus pre-determined settings on the other
side
Completely variable placement on both sides
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ImproveStep 4: Pin & Place Method Conveyor Rails Results
34 m
in8 m
in
NEW - 8 min
Pull securing pins
Move rail to appropriately marked width
Replace pin
Start production
OLD - 34 min
Loosen screws with 1/4” wrench
Slide rails into place using a bottle as the guide
Tighten screws with 1/4” wrench
Start production
Bottle jam
Continue production
Yes
No
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ImproveStep 4: Centering Method
Fixture
Machine Center
Adjustments
Machine Base
Fixture
Machine Base Centering BallOr Notch
Machine Center
Before After
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ImproveStep 4: Centering Method Results
Load & cut part
Correctdimensions
Make adjustments
Start production
Place fixture onto base
Take measurements
8 m
in
Before
Start production
Place fixture onto base centering using
centering ball
1 m
in
After
Average 2 Scrapped Parts
0 Scrapped Parts
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ImproveStep 4: Cap Sealer Height Setting
CONVEYOR
SEALER
Set Screw
SETTING
No indication of settings for specific bottle sizes
10 minute procedure with average 2 to 5 adjustmentsUp to 5 Bottles Scrap!
Indication and slots for each bottle size
CONVEYOR
SEALER
Pin
SETTING
50 cc
100 cc
150 cc
30 second procedure with zero adjustments
0 Bottles Scrap!
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ImproveStep 4: Machining Setting Checklist
Provide vehicle for converting settings based on intuition to settings based on fact!
PART # BASE SETTING FIXTURE
327-01 10 2B
493 8 2C
1141 6 1.1A
PI482.3 11 3A
Milling Machine M-25 Setting Checklist