Supplier Development
Setup Reduction Guide
Process Development
FUNDAMENTAL RULE #1
We will NOT sacrifice Quality or Safety to reduce setup time.
FUNDAMENTAL RULE #2
If an ACTIVITY can be done when the process is running (externally),
then it should be done while process is running.
Brainstorm and prioritize new ideas (Setup
Reduction Ideas):
The set-up team will review the current set-up documentation and look
for areas of improvement. Typical areas to focus include:
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Job assignments and staffing
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Travel distance
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Set-up tooling
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Inspection and qualification
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Work instructions
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Housekeeping and organization
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Mounting and clamping
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Alignment and centering
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Containers and material handling
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Standardization
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Pre-staging
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Conversion from internal set-up elements to external
The Supplier Development engineer must insure that safety and part quality
are never sacrificed to obtain reductions in set-up times.
Reduce/improve both internal and external activities:
Internal
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Standardize Fixtures / Die Heights
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Use Locating Pins
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Predetermined X-Y coordinates
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Standardize & Improve Clamping Methods
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U-Washers
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T-slot and U-slots in base plates
External
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Eliminate adjustments
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Maintenance of tools, gages & fixtures
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Preset tools and positioning die blocks
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Assign additional people to setup when feasible
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Pre-stage all items - Die carts, tool boards, get tooling, fixtures, dies,
and molds
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Dismantle and Repair Items
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Clean up
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Pre-Deliver Paper Work
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Easy Access to Required information
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Last Modified on: Thursday, 25-Aug-99
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