Set‐up time reduction and mistake proofing methods – A study of application in a small company

Abstract

The paper reports a study into set-up time reduction and mistake proofing methods in a small company involved in the machining of precision components in small batches with high variety for the aerospace industry. The company has made some set-up reductions mainly using work study related methods and in one manufacturing cell by the use of the Single Minute Exchange of Die (SMED) methodology. Mistake proofing devices in the form of fouling pins and offset holes have been developed for the family of components manufactured in this cell. Until recently the set-up times were not measured and worse still were considered as productive hours. As a consequence, there was a lack of awareness and motivation amongst operational personnel to reduce set-up times and knowledge of SMED was limited to a small group of individuals. This, along with the lack of investment in mechanisms to aid set-up time reductions and prevent errors, has restricted the use of this type of methods and technology. However, there is evidence that the demands made by the company's major customer will lead to increased efforts to put into place these types of changes.

Non-valued Changeover Time Measures for Hiddxen Time Loss in Automotive Mechanical Component Production

“…In the case of internal setup for new model, the commonly used activities are tool fastening, tool contacting and setting process. In this manner, the attachment done in actual (fastening and contacting) or dies removal or tooling are categorised as an setup time internal activities [21]. Patel et al [22] indicated another aspect that must be considered significant for time loss in machine setting is the possibility of error.…”

Estudo De Tendências E Impacto De Inovações Em Técnicas De Redução De Tempo De Setup via Aplicação De Mineração Tecnológica

“…A equipe da Universidade de Bath trabalhou com uma série de indústrias e teve como principais resultados: metodologia geral de troca rápida de ferramentas dividida em 3 estágios, catálogo de 200 ideias de melhorias de setup, procedimento de análise para justificativa financeira e outros benefícios de redução de setup, método de auditoria de maquinário e de linha de produção como um todo. Outros trabalhos, como o de Ulutas (2011), Cakmakci (2009), Patel et al (2001) tiveram abordagem representativa sobre estudos de caso sobre diferentes ramos industriais, embora somente Ulutas tenha constatado numericamente os ganhos produtivos da metodologia aplicada.…”

Moving from lean manufacturing to lean construction: Toward a common sociotechnological framework

“…Third, reduction of set-up activities, single minute exchange of dies, reduces the activities to be performed during downtime so that changeovers do not interfere with minimum batches. Planned critical activities supported by single minute exchange devices (SMED) should reduce the effect of alternating different products (Patel, Shaw, & Dale, 2001).…”