Document the new method:
It is critical to document the new method in a step by step fashion in order to insure consistent set-up rates. The use of film and digital photos could be used as a means to simplify set-up documentation. The Supplier Development engineer may wish to conduct a “LEGO”? exercise with the set-up reduction team in order to emphasize the need for accurate set-up instructions. In the “LEGO”? exercise, several teams are asked to build a simple assembly, such as a policeman driving a three-wheeler. One team is given the assembly instructions and asked to leave the room. The remaining teams are given the kits with no instructions. The typical result is that every team, except the team with the instructions, build the assembly wrong.
Other examples (Ed)
Implement the new method:
Do not implement the new set-up method without the approval of supplier management and the set-up reduction team. Be sure to communicate the new method and train the appropriate personnel. At this time it is allowable to implement the new method on duplicate machines.
Collect data on the new method and
compare to the baseline:
The set-up team will compare the set-up metrics of the new method to the previously recorded metrics of the initial method. The change in set-up performance rates will be calculated and published.
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Last Modified on: Thursday, 25-Aug-99
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