質(zhì)量管理第7講森口體系-文庫吧資料
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【正文】 in this system is in the risk perception loop. ? If we can make setups fast, easy and predictable the loop reverses into a virtuous cycle. Easy setups encourage small lots and small lots mean more setups which increases confidence and setup skill. In addition, the piece cost loop bees very weak. ? As a result, inventory es down and scheduling is easier, The flow of costs into the Black Hole slows as people spend less time expediting, searching and chasing. 3/16/2023 11 How To Reduce Setup Time ? Setup reduction should be approached in four phases or stages as illustrated below. Is is usually best to repeat the process through several iterations spaced several months apart. 3/16/2023 12 How To Reduce Setup Time 3/16/2023 13 1. Maintenance, Organization and Housekeeping ? It often happens that setup problems are related to poor maintenance such as worn parts, worn tooling, dirt, or damaged threads. Disanization and poor housekeeping are also contributors to setup problems. These are easy to fix and should be a first step. 3/16/2023 14 2. Internal Elements to External ? Internal elements occur when the machine is down. Examine each internal element and see if it cannot be done externally. For example, the preheating of an injection molding die could be done before it goes into the machine. 3/16/2023 15 3. Improve Elements ? Here we examine every element to see how we can eliminate it, simplify it, reduce the time required or improve it in some other way. 3/16/2023 16 4. Eliminate Adjustments ? Adjustments are often the most time consuming, frustrating and error prone parts of a setup. There are many ways to eliminate them entirely and this is the ultimate goal. 3/16/2023 17 Setup Reduction Typical Results ? Setup reduction (SMED) techniques apply across many industries and process technologies. The list below shows some examples. 3/16/2023 18 Industry Equipment Before After % Assembly Adhesive Applicator 12:09:00 0:21:00 97% Assembly Air Cleaner Assembly 2:00:00 0:00:00 100% Cosmetics Capper Machine 0:09:36 0:03:21 65% Electronics PCB InserionICs 0:13:30 0:05:56 56% Electronics PCB InsertionAxial 0:05:18 0:04:18 19% Electronics PCB InsertionRadial 0:54:12 0:05:06 91% Foundry Molding Machine 0:10:00 0:06:12 38% Metal Cutting Casting Drill 1:00:00 0:09:00 85% Metal Cutting CNC MILLING 2:00:00 0:00:00 100% Metal Cutting FADAL HMC 1:45:00 0:15:20 85% Metal Fab 40 Ton Press 0:48:00 0:04:00 92% Metal Fab 750 Ton Hyd Press 2:10:00 0:42:00 68% Metal Fab 800 Ton Press 6:00:00 0:10:00 97% Metal Fab Aluminum Extruder 1:09:00 0:02:12 97% Metal Fab Brake Press 0:37:00 0:04:00 89% Metal Fab Draw Press 1:30:00 1:00:00 33% Metal Fab Edge Trim Press 0:24:00 0:04:00 83% Metal Fab Pilot ChangeMuffler Press 0:07:00 0:00:15 96% Packaging Flex Packaging Line 3:00:00 0:10:00 94% Paper Sheeting 0:03:00 0:00:36 80% Pharmaceutical Centrifuge 0:12:00 0:02:12 82% Plastics 250 Ton Injection Molder 1:06:00 0:09:12 86% Plastics Injection Molder 2:30:00 0:06:00 96% Plastics Injection Molder 2:00:00 0:03:00 98% Printing Kidder 6Color Web Press 4:20:00 1:10:00 73% Printing Press Make Ready 9:30:00 4:20:00 5
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