Documentos de Académico
Documentos de Profesional
Documentos de Cultura
CONTENTS
INTRODUCTION
Mold Change Colour Change 0 Mold change 1st Piece Time (good or bad)
EQUIPMENT
Available time
Setup/ adjustment Idling/minor stoppages Speed Defects in process rework Start-up losses
INTRODUCTION
History : Land costs in Japan were very high, therefore it was not feasible to store large inventories of vehicles
Reduces the waste of inventory by creating shorter production runs that better align with customer demand
TRANSFORMATION
Extraction
The removal of the tooling, raw material, and support equipment after the production lot is completed.
Mounting
The placement of the new tool, support equipment, and raw material before the next production lot.
Setting all the process control settings prior to the production run.
This includes the necessary adjustments required after the first trial pieces are produced.
Setup Improvement
The time after processing during which the tooling, machinery is cleaned, identified, and tested for functionality prior to storage.
INTRODUCTION
SMED:
Single Minute Exchange of Die Concept that says all setups should and can take less than 10 minutes
OTED:
One Touch Exchange of Die Concept that says all setups should and can take less than 100 seconds!
We should always:
Notify the party to be observed ahead of time Explain why we are conducting an observation Were observing the activity not the person What we are trying to accomplish Identify internal and external elements, waste/lost time, variances from the standard process Explain the possible benefits for them and the company Review the observation with the individual Coaching Clarification
All Setup
Activities
Run
Run
Internals
Run Externals
Internal elements: operations that must be performed while the machine/process is stopped External elements: operations that can be performed while the machine/process is running
Externals
Internals
Run
Externals
Internals
Run
Eliminate adjustment
Externals
Internals
Run
Externals
Internals
Run
Eliminate search-and-find work Arrange tools & materials beforehand Complete prep work before starting changeover Standardize settings Make visual marks vs. trial and error adjustments Eliminate trial runs Postpone put away work
Machine running
BEFORE
Machine running
STREAM LINE
Machine running
Machine running
Total setup
one motion fasteners levered or one-turn fasteners interlocking wedge or slot use angle and flat use preset pins, guides, notches etc. Use POUS and water spider
Visual factory locations for tools Color coding Standard set ups Checklists ADOPT QUICK DIE CHANGEOVER ( QDC) HARDWARE
Eliminate adjustments
Tools Turntable
Documentation
Slot address
Model
Slide value
Adjusting pin
Spring plate
Better
Better Still
4-piece clamp
Die heights vary
4 3
Spring
BEFORE
L clamp
Standardize clamp heights on dies
Spring Die
Bolster Plate
After
Eliminate bolts
QUICK RELEASE CAM LOCK TOGGLE LOCK DOWN CLAMP
After
Bolster
Top view
2. Tighten
Hinged Bolt
Side view
1. Lift
TBM
E xte rn a l P re -S e tu p C h e c k lis t
C o re M a ch in e # 5 A ll Ite m s P re -S e tu p 1 0 M in u te s B e fo re S e tu p
R es po n sib le P ers on
S up e rviso r
P re -S etu p Item s
S ch e du le sh o w s n ext 3 s etu p s
P re -S etu p Item s
R es po n sib le P ers on
A ir h o se , bo th sid e s o f m ac h ine
S etu p P e rso n
S etu p P e rso n
S etu p P e rso n
A ll a rea s cle a r a n d re a dy fo r s e tu p
S etu p P e rso n
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