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Machine set up

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  • #38961

    Johnny Guilherme
    Participant

    To all the set-up reduction (single minut exchange of dies) experts. I am busy doing a set-up reduction excercise on a blister packaging machine. What are the true benefits of reducing set-up???. I am talking especially about monetarory benefits.
    Also where could one get videos or educational material showing companies that have addressed machine set up and now have changes overs done in less than a minute. It would be nice to see how the experts are changing over “quickly and effeciently” on a piece of equipment.
    Johnny
     
     

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    #117452

    Diaconu
    Participant

    One real benefit is the lower the set up time the shorter the ‘production run’ you can make and still remain cost effective. The outcome of that is that you can, for the same production cost, make smaller batches, hold less inventory and be more responsive to your customers. Set up time combined with production can be used to give you a minimum cost effective length of production under those settings. You can probabaly get a ‘maximum’ by considering when the effect of production time on yield loss ceases to show any discernible change.
    If you had zero change over time and no start up loss you could make single unit production runs. Of course that is practically unlikely to happen. But improving both can maximise flexibility at no loss to operating costs.
    Mia

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    #117453

    Mike Carnell
    Participant

    Johnny,
    Ulices is in RSA and can help you with this. Either Scot or Ulices will have my phone so you can reach them on my number.
    Regards

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    #117500

    Johnny Guilherme
    Participant

    Mia hi thanks for responding.
    The situation with this line is that we already are doing “short” runs according to our production manager. The issue lies in having the machine down for such long periods of time and hence at times having to run overtime because of shoratge of capacity. One obvious way of reducing the setup(i.e.an immediate benefit) is by introducing a second setter of which at this stage i cannot justify. Its the cost of a setter versus the cost of downtime on the machine. Surely the overhead on that machine (when the machine is not running) is much more than employing another setter. This is what i am looking at. If i can employ a second setter i could possibly reduce the set up by at least 40%. At this stage i have asked the cost accountants for the overhead cost and the number they gave me is very small.
    I have videod the whole set up and will be doing a time and motion study on the set-up. So there will be more improvements that will be done.
    Regards
    Johnny

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    #117501

    Johnny Guilherme
    Participant

    Mike
    Thanks. I did try to contact Ulices but was not successful. I will try again.
    Regards
    Johnny

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