Setup & adjustment loss

Key points for the improvement
of Change-over times.

Where ever possible, externalize!

1. Preparation

1) What can be prepared prior to set-up?
All necessary jigs, tools and parts stored on a dedicated “change-over trolley” - Can we color code such items for different products/pack sizes ?
2) Move hands, but do not move feet.

Set-up :

1) We hate bolts! Bolts are the enemy!
Minimize number of bolts - Examine requirement of bolts
Minimize types of bolts - Standardize bolts so that it reduces the number of tools required to unfasten it Minimize amount of thread Loosen, not unfasten Minimize repositioning of spanner on bolt head whilst undoing or tightening. Use tools that don’t require repositioning (wing nuts, ratchets etc)
Boltless construction - one touch (clamps, cams, plungers etc)
- no touch (mechanize)
2) Minimize number of change-over parts (convert to modular type)
3) Standardize jigs and tools
4) Improvements to make simultaneous change-over possible
5) Improve standardization of set-up procedures - Make Multiple activity chart.
6) Optimize ratio between amount of work and number of people
7) Practice set-up procedures (increase skill levels)

Adjustments :

1) Mechanization
2) Simplification of work - mark set values on scales, use block gauges, spacers, stops etc.
3) Use visual controls
4) Clearly identify and maintain datum faces - eliminate dirt, wear, damage, rust etc.
5) Do not move die and jig reference stops.
6) Improve work practices - procedures, tools etc
7) Practice adjustment work - increase skill level