Setup time is the time taken to switch from one job to another. Reducing setup time can increase productivity and profits. There are two types of setup time: external and internal. Methods to reduce setup time include quick-change molds and tooling, CNC programming, and pallet changing. Proper training, easy access to information, and availability of materials and tools can improve setup time.
Setup time refers to the elapsed time from the last production unit in a job to the first valid unit in a new job. More specifically, it is the time required to remove dies and tools from a work order and replace them with dies and tools for the new job. Exchange rate, turnover and preparation time are some of the common names for it. While it usually refers to production machinery, setup times can refer to other types of activities, such as the time it takes to change band equipment on stage. Toyota introduced a campaign to reduce installation times in 1971 and many other manufacturers have since followed its lead.
There are many reasons to reduce installation time. While the initial cost can be expensive, manufacturers have found that reducing turnover times increases productivity and profit. Many companies have moved to just-in-time or JIT processes and having fast turnaround times helps them achieve their 100% customer satisfaction goals. Fast setup times also mean workers have less free time, such as time to roam and talk.
The ability to quickly set up a new job means a company can run multiple products on the same machine, saving money and increasing profits. There are two types of setup time: external and internal. External setup times are the parts of the changes that a worker makes while the machine is running. Internal time is the amount of time a worker uses while the machine is idle. The goal is to shift the internal to external percentage of time to continue production while preparing for installation.
The types of methods that can help reduce installation time are highly dependent on the type of business and the type of process. It will be different for a person working in an office than for a machinist in a manufacturing facility. Some examples of ways to reduce setup time include quick-change molds and tooling, computer numerical control (CNC) programming, and pallet changing. Sometimes it can be as simple as using a two-person team to make the switch. Other methods include standardizing bolts and studs to fit multiple machines, having tools and equipment nearby, and using power tools rather than hand or hand tools.
Regardless of what camp your setup time falls into, there are a few basic rules that can improve any step. Proper training ensures that the worker is using the latest and most efficient method. A worker needs easy access to information about the new setup and the method needed to complete it. Materials for the new job must be available and tools, molds or fixtures stored nearby in easily accessible spaces. These simple steps help workers get as much done as possible during outdoor weather.
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