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Time Reduction
SETUP TIME REDUCTION
The
fundamental goal of contemporary Just-In-Time (JIT) manufacturing
is frequent delivery of small lots of material. Setup Time Reduction
is the most important of technologies that enable JIT replenishments
while raising productivity, lowering inventory, slashing lead time,
and improving quality.
Quick setups drive smaller lot sizes, make additional capacity
available (often at bottleneck resources), reduce scrap and rework,
and increase flexibility. World Class performance ultimately relies
on many techniques and disciplines working together, but it must
all begin with fast setups.
Equipment operators and setup technicians are an organization's
best resource for making this happen. TCA's proven methodology demonstrates
the importance of fast setups and teaches operators as well as technicians
how to accomplish this goal.
Objectives
To support a broad-based WCM application, these objectives will
be essential:
• Achieve setups of under 10 minutes, particularly on constraint
equipment
• Commit to fast setup through training and employee involvement
Approach
TCA’s approach to meeting these objectives involves a series
of carefully managed, time-phased activities:
Project teams will be trained in the following setup time reduction
process:
TCA Contributions
• Educate management in the significance of quick setups
to obtain buy-in and leadership
• Work with you to ensure the setup time
reduction effort is properly integrated with other World Class initiatives
• Coach operators and setup technicians
• Help set up documentation systems and measurements
to monitor gains and continuous improvement
Benefits
• The entire organization will develop greater understanding
of setup time reduction and its critical role in World Class performance
• Careful selection of pilot projects will yield immediate
decreases in lot sizes and recapture of capacity at bottleneck
resources
• This effort will demonstrate the value of employee involvement
and management's commitment to the overall WCM initiative
• The groundwork will be in place to achieve setups of
under 10 minutes
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