UNit 6

Question 1

How do you prevent failures? SMED

Answer 1

• design out fail points
• build in redundant systems
• use failsafe work methods
• perform maintenance
• mitigate risks

Question 2

What is setup?

Answer 2

when a machine, work center, cell or assembly line is made ready to switch from production of the last good piece of the last lot to the first good piece of a new lot.
(changeover)

Question 3

What are the steps in a set up?

Answer 3

1. prepare, adjust and check
2. remove old tooling and install new tooling on the machine
3. measure, set and calibrate
4. produce initial parts and adjust the machine

Question 4

What are the traditional strategies used to improve the setup process?

Answer 4

• try to make setup processes as fast as possible

- increase production lot size

Question 5

What is a skilled based strategy?

Answer 5

• using a specialist to reduce changeover and setup times
• dependence on specialists are strong
• not all the tasks that they do are critical

Question 6

What is large batch-based strategies?

Answer 6

-the larger the batch size the smaller the impact of the set up time will be on the production cost

Question 7

How do you calculate set up cost per unit?

Answer 7

a single units production time +set up time/batch size

Question 8

Explain the difference between external and internal setup?

Answer 8

external : operations that can be performed while the machine is still processing
internal: operations that can be performed when the machine stops

Question 9

What the are strategies companies use to reduce changeover and setup times?

Answer 9

Skilled based strategies
large batch-based strategies
economic lot size strategy

Question 10

What is economic lot size strategy?

Answer 10

direct relationship between the inventory cost and the setup cost, based on setup time being constant.

Question 11

What is the SMED Method?

Answer 11

grouping of internal and external setup as well as the stages preliminary, first, second and third

Question 12

What is a preliminary stage in SMED?

Answer 12

studying the current setup process in order to better understand what can be improved on
-collect data on setup times

Question 13

What is the Stage 1 in SMED?

Answer 13

-separating internal and external setup

Question 14

What is the Stage 2 in SMED?

Answer 14

• converting internal setup to external set up
• reevaluate the internal setup operations to see if they missed categorized
• look to see if they can be carried out in part while the machine is still running

Question 15

What is the Stage 3 in SMED?

Answer 15

• improve all aspects of the setup process

- trying to reduce duration of external and internal times and eliminating some unneeded operations

Question 16

What are tools used in the first stage of SMED?

Answer 16

check lists; questionnaire that should be checked before each setup process
check panel; a panel used to see if tools are missing that are needed
function checks: checking to ensure status of die and tools to ensure they are clean and in best working order
part & tool transportation improvements; making sure the new parts are at the machines waiting to be exchanged with the old. Cuts down on idle time.

Question 17

What are the tools used in the second stage?

Answer 17

endless material method; when able try to make rolls or coil feeds endless and tied to the first so that there is no need to replace.
temporary containers: when endless cannot be used, these containers save time by not having to look for new parts to replace the old ones with.
press-die preheat: preheating a mold before it is needed therefore eliminating that process in the setup because it is already done.
Function Standardization : standardizing measurements of molds for easy installation
tool duplication

Question 18

What are the tools used in the third stage?

Answer 18

Streamline external setup: improving the tool storage by using the 5s’s .
Streaming internal setup: parallel operations, if their are needs in setup at the front and back of a machine employ another worker so that there is no waste moving from front to back.
one motion method
functional clamps: using screws with one thread to lessen time wasted in unfastening screws and nuts.
eliminating testing procedures and adjustments

Question 19

What are the effects and benefits of SMED?

Answer 19

• easier setup process; new setup procedures, operations can be carried out by majority of employees, increased safety, eliminating defective parts
• reduced batch sizes and WIP
• increased productivity & flexibility
• workplace task simplification; easier to locate tools, cleaner environment