Set-Up-Time Reduction

Shorter Lead Time, Lower Inventories, On-Time Delivery, The Ability to Change Quickly

By: Jerry W. Claunch

Write A Review

Hardcover | 26 June 1996 | Edition Number 1

At a Glance

Hardcover
200 Pages

Dimensions(cm)
23.11 x 16.0 x 2.41

Hardcover

RRP $85.95

$72.75

15%OFF

or 4 interest-free payments of $18.19 with

Ships in 25 to 30 business days

Manufacturing companies today are feeling intense pressure to increase their productivity and until now, had a proven guide to point them in the right direction. Set-Up Time Reduction lays out a simple method for increasing actual manufacturing time and bottom-line profits by reducing production set-up times by as much as 30 percent.
Set-Up Time Reduction is an easy-to-read handbook for everyone involved in the manufacturing process from supervisors to frontline workers. It combines actual work experiences and applicable systems that are designed to help you initiate your effort by defining a vision, tapping the resources within by working in teams, supporting your employees through empowerment, and implementing problem-solving methods; calculate your return-on-investment benefits as a result of set-up time savings that can reach up to 90 percent; organize and store your set-up materials in the most efficient manner according to your company's specific needs; adopt a quality focus that results in complete customer satisfaction; a low cost product with correct counts and no defects, delivered on time; and reduce cycle time now and for years to come.

Shipping

	Standard Shipping	Express Shipping
Metro postcodes:	$9.99	$14.95
Regional postcodes:	$9.99	$14.95
Rural postcodes:	$9.99	$14.95

Orders over $79.00 qualify for free shipping.

How to return your order

At Booktopia, we offer hassle-free returns in accordance with our returns policy. If you wish to return an item, please get in touch with Booktopia Customer Care.

Additional postage charges may be applicable.

Defective items

If there is a problem with any of the items received for your order then the Booktopia Customer Care team is ready to assist you.

For more info please visit our Help Centre.

You Can Find This Book In

Non-Fiction Business & Management Management & Management Techniques Management of Specific Areas Production of Quality Control Management Accounting & Finance Accounting Management Accounting & Bookkeeping Engineering & Technology Technology in General Engineering in General Mechanical Engineering & Materials

Production & Industrial Engineering Mechanical Engineering Industrial Chemistry & Manufacturing Technologies Industrial Chemistry Ceramics & Glass Technology

Preface	p. xi
Lessons Learned	p. 1
Speed and Results	p. 2
Discretionary Time	p. 3
Vision	p. 4
Issues to Address First	p. 4
Hand Tools	p. 5
Fasteners	p. 6
Perishable Tools	p. 9
Forming Dies, Tools, Tool Holders, and Change Parts	p. 9
Fixtures, Dies, Face Plates, Printing Cylinders, Forming Tools, and Chuck Jaws	p. 10
Maintenance of Parts, Tools, and Fixtures	p. 12
Lubricants, Chemicals, and Solvents	p. 15
Guard Removal	p. 16
Scrap and Rework	p. 17
Standardization of Set-Up Procedures	p. 18
Making and Delivering the Change Parts in Kits	p. 18
Establishing Standard Tool Lengths	p. 19
Establishing Standard Tooling	p. 19
Establishing Standard Locations	p. 20
Establishing Standard Routing	p. 20
Thirty Percent Reduction in Set-Up Time Accomplished!	p. 20
Calculating the Return on Investment of Set-Up Time Reduction	p. 23
Where to Start	p. 28
How Do You Start?	p. 31
Change from Within Gets Accepted	p. 31
Total Quality Management	p. 32
Problem-Solving Method	p. 34
Steering Committee	p. 35
Additional Information about Approvals	p. 40
Empowerment	p. 41
Tapping the Resource Within	p. 42
How Do You Get People to Help?	p. 44
Turning Negative People into Positive People	p. 45
People Enjoy Rallying	p. 46
Getting the Results	p. 47
What Do We Need to Know?	p. 48
What Do We Need to Do?	p. 48
Assignments	p. 48
Decisions Made	p. 49
Get Input from Everyone	p. 49
Tools that Work	p. 50
Baselining	p. 50
Videotape the Setup	p. 50
Documentation of the Setup	p. 53
The Improvement Process	p. 57
Eliminate Quality Problems	p. 58
Eliminate Unnecessary Elements	p. 59
Eliminate the Nonvalue Added Elements	p. 60
Move Elements to External	p. 62
Reduce All Remaining Internal Elements	p. 66
Reduce All External Elements	p. 67
Part Families	p. 67
Documentation and Data Entry	p. 68
Change Part Maintenance	p. 68
Change Part Location/Kitting	p. 69
Remaining Elements	p. 71
Quality Acceptance of the First Part	p. 78
Automation	p. 78
Standardized Procedures	p. 79
Application Improvements for Equipment	p. 81
Focus Set-Up Time Reduction on a Part Number or Machine?	p. 82
Equipment Wear	p. 82
Cleaning Up	p. 84
Adjustment	p. 85
Fasteners	p. 85
Tooling Needs	p. 86
Toolbox Clean Out	p. 88
Tool Storage	p. 88
Quick Disconnects	p. 89
Standardized Components	p. 89
Alignment	p. 90
Tool and Fixture Positioning	p. 91
Clamping	p. 92
Tool Presetting	p. 93
Travel Time	p. 93
Trial Runs	p. 95
Stress Forces	p. 96
Dedicated Equipment	p. 96
Equipment Maintenance	p. 97
Automation	p. 98
Supporting Set-Up Time Reduction	p. 101
Quality Improvements	p. 101
Value Analysis/Value Engineering	p. 104
Concurrent Engineering	p. 105
Never Assume	p. 105
Communication and Cooperation	p. 106
Floor Layout	p. 107
Data Entry	p. 107
Paperwork	p. 107
Scheduling	p. 108
Team Staffing	p. 109
Supervision	p. 109
Commitment	p. 110
Training	p. 111
Checklists	p. 111
Procedures	p. 111
Newsletter	p. 112
Decisions that Affect Set-Up Time	p. 112
Support Area Response	p. 112
Material Handling	p. 113
Criticism	p. 113
When You Cannot Videotape	p. 114
Kanban Inventory Method	p. 114
Measurements	p. 115
Workforce Reduction	p. 116
Special Teams: SWAT and Rapid Response	p. 119
Questionnaires	p. 120
Holding the Gains	p. 121
Documentation	p. 121
Celebrate Improvement by Making It a Big Deal	p. 124
Steering Committe Reviews	p. 124
Field Trips to the Factory	p. 125
Transferability (Cloning)	p. 126
Rewards, Awards, and Other Motivations	p. 126
Continuous Improvement	p. 133
What Should You Expect from Set-Up Time Reduction?	p. 135
Resistance at First	p. 135
Frequent and Continued Improvements	p. 135
Breaking Down Barriers (Team Building)	p. 137
Commitment	p. 137
Stages of Employee Attitude	p. 137
Management Stages and Attitudes	p. 137
Produce as Needed	p. 139
Increased Run Time (But Be Careful)	p. 139
Preventive Maintenance Time	p. 140
Scrap Reduction	p. 141
Rework Reduction	p. 141
Equipment Purchases	p. 142
Reduced Inventory	p. 142
Performance Charting	p. 143
Productivity Improvements	p. 144
Team Building	p. 144
Breaking Down of Barriers	p. 146
Inventory Turns	p. 147
Space	p. 150
Flexibility	p. 150
Customer Delight	p. 151
Flexible Scheduling	p. 152
Savings	p. 153
Product Involvement	p. 153
Cycle-Time Reduction	p. 154
The Team Experience	p. 155
We Need More Ricardos	p. 155
Attitude/Assurance	p. 156
The Culture	p. 156
Commitment	p. 157
Authority and Responsibility	p. 158
Team Membership	p. 159
Decision Making Based on Fact	p. 161
When Things Slow Down or You Feel Like Quitting	p. 161
Distractors, Procrastinators and Other Influences	p. 163
Managing and Supervising with Teams	p. 164
Where's the Band?	p. 165
This is My Team, I Have Ownership to its Performance	p. 166
Management: The Boss is Key	p. 166
Satisfaction in a Job Well Done	p. 167
How to Make It Fail	p. 169
Don't Train the Team	p. 169
We Don't Have Time	p. 170
A Few People on Too Many Teams	p. 170
Allow Management to Skip Meetings	p. 172
Don't Let the Team Make Decisions	p. 172
Don't Take Assignments	p. 173
Don't Get Assignments Done	p. 173
Don't Discuss It	p. 174
Criticize instead of Encouraging	p. 174
Work outside Your Career System for Approvals	p. 175
Don't Promote Set-Up Time Reduction Once It Is Started	p. 176
Don't Measure Progress	p. 176
Make Reporting Difficult	p. 177
Don't Follow Up or Motivate	p. 177
Make the Focus Indefinite Then Quit	p. 177
Do It for a While Until It Just Fades Away	p. 178
Have "Team of the Month"	p. 178
Don't Go Out to Shop to See Results	p. 178
Don't Recognize Accomplishment	p. 179
Don't Hold the Gains	p. 179
Don't Encourage Low-Cost Solutions	p. 180
Second-Guess Team Decisions	p. 180
Don't Follow a Proven Method	p. 180
Conclusion	p. 181
Most Frequently Asked Questions	p. 183
Index	p. 207
Table of Contents provided by Syndetics. All Rights Reserved.

Set-Up-Time Reduction

Shorter Lead Time, Lower Inventories, On-Time Delivery, The Ability to Change Quickly

At a Glance

Hardcover

Shipping

How to return your order

Defective items

You Can Find This Book In

More in Ceramics & Glass Technology

Additions to Clay Bodies : New Ceramics

New Ceramics

Special Effect Glazes

New Ceramics

Engineered Ceramics and Composite Materials

From Fundamentals to Applications

Additive Manufacturing of Advanced Ceramic and Ceramic Matrix Composites

Current Status and Future Developments

Industrial Composites, Optimization Methods, and Tribological Considerations

Manufacturing Design and Technology

Glass Photonics

Materials, Properties, and Applications

The Undiscovered Self : Answers to Questions Raised by the Present World Crisis

Answers to Questions Raised by the Present World Crisis

Raman Spectroscopy Applied to Polymer Composites and Nanocomposites

Woodhead Publishing in Composites Science and Engineering

Natural Composites for Biomedical Applications

Woodhead Publishing in Biomaterials

Next Generation Materials

Recent Advances in Engineering Sciences

Computational Methods for the Multiscale Modelling of Soft Matter

Raise Your Glass

28 Stained Glass Projects, Patterns and Tutorials

Polymer Nanocomposites

Interface Engineering of Carbon Nanotubes, Advanced Properties and Recent Applications

Advances in Ceramic Matrix Composites

Woodhead Publishing Series in Composites Science and Engineering

Elastomer-based Composites and Nanocomposites

Fundamentals, Recycling and Applications

Next Generation Materials

Recent Advances in Engineering Sciences

Low Cost Ceramic Membranes

Materials and Fabrication Processes

Geopolymers

Chemistry

Wild Clay

Creating Ceramics and Glazes from Natural and Found Resources

Kicking Glass

A Creative Guide to Stained Glass Craft

Ceramic Artists on Creative Processes

How Ideas Are Born

Sintering of Ceramics

Design and Create Contemporary Tableware

Making Pottery You Can Use

Mathematical Property Models in Polymer Composite Materials

Woodhead Publishing in Composites Science and Engineering

This product is categorised by