Setup time reduction in a just-in-time manufacturing environment
| dc.contributor.author | Abrams, Hilton Mark | |
| dc.date.accessioned | 2014-08-26T08:42:48Z | |
| dc.date.available | 2014-08-26T08:42:48Z | |
| dc.date.issued | 2014-08-26 | |
| dc.description.abstract | Setup time reduction Is an essential activity used to prepare the facility for just-in-time (JIT) manufacturing; the aim oZ which Is to assist In meeting the desirable manufacturing requirements of delivering low cost quality products on time. (20) The Japanese have shown that setup reduction eliminates the need for setup skills and producing In large or "economic" lot sizes. (1 ) It is usually the case that preparation and adjustments, which usually account for 95% of the setup time, can be externalised or eliminated. (1) The overall production process should be examined before setup times are reduced on existing equipment. (2) Considerations Include group technology, setup sequencing, dedicated machines identifying bottlenecks (stated by OPT) and the 80/20 rule. A training programme should be initiated where setup reduction teams, consisting of production operators, setters, foremen line supervisors and production engineers, are educated in JIT manufacturing, the changing business environment and recording and analysis methods. (31) A theoretical approach to setup reduction has been formulated by Shlgeo Shlngo. (1) During the preliminary stage Internal and external setup are not distinguished, therefore this stage involves a work/time study of the existing setup and activity categorisation. From this, potential externallsatlon or elimination of setup operations can be determined. The first stage of setup reduction involves separating internal and external operations. During this stage tooling organisation and pre-preperation activities are converted to external operations. The second stage of setup reduction involves converting internal to external setup. A simple Pareto analysis is conducted to determine time consuming activities, which are then tackled first. This stage includes equipment modification, standardisation of procedures, parallel operations and elimination of adjustments. The third stage involves streamlining setup operations by improving operations and initiating setup practise sessions. All ideas should be documented and implemented immediately. Setups should be kept in mind when buying new equipment, however it is usually more beneficial to modify existing equipment in-house. (4) Setup reduction costs are low at first for large time reductions, but costs become high yielding small returns during the final stages of the programme. (31) It may be beneficial to introduce an incentive scheme where members of setup teams receive recognition and a financial reward for implemented ideas. (34) A setup reduction programme was implemented at Viro Looks, the aim of which was to illustrate the theoretical approach to setup reduction. Setups were reduced here on a transfer machine by 67%, 60% time savings being achieved at low/no cost. A survey was performed involving 18 leading JIT companies, where it was found that the majority (14 companies) have initiated a setup reduction programme. However many of these companies have only limited experience in setup reduction and, according to the survey, require 4-6 years to reach the final stages of setup reduction. | en_ZA |
| dc.identifier.uri | http://hdl.handle.net/10539/15256 | |
| dc.language.iso | en | en_ZA |
| dc.subject.lcsh | Just-in-time systems--South Africa | |
| dc.title | Setup time reduction in a just-in-time manufacturing environment | en_ZA |
| dc.type | Thesis | en_ZA |