Setup Time Reduction Research Articles

Lean manufacturing: ações de melhorias em empresa metalmecânica

The current industrial scenario in Brazil stimulates competition among companies therefore, aiming at survival in the market and their potential growth, organizations are obliged to seek alternative tools and solutions. The Lean Production System (SPE) has received great attention worldwide due to the results obtained in large corporations with regard to waste reduction and cost reduction. In this context, the present work has the purpose of proposing the application of Tools of the Lean Production System (SPE), through the analysis of the production process of a metal-mechanic industry located in the state of Parana - PR, Brazil, and specialized in the production of a line of sprayers for agriculture. Based on the bibliographic research of the techniques and tools that structure the SPE, a case study is presented. The proposal of the tools to be applied was developed, according to the conditions found in the studied company. It proposed the implementation of the 5 S Program; the layout adaptation and the Rapid Change of Tools as premises for the subsequent implementation of other SPE tools. Some actions were initiated, bringing significant results to the company, as better organization of the sector, reduction of the productive lead time by 25% and reduction in setup time, improvement in production time, better organization, making it possible to standardize production orders.

The effect of Lean Six Sigma practices on food industry performance: Implications of the Sector's experience and typical characteristics

Lean, Six Sigma and Lean Six Sigma initiatives (L&SSi) have been adopted by different industry and service sectors to improve companies' performance and competitiveness; however, adoption in the food industry is still very low. The sector lacks familiarity with the L&SSi initiatives; it views “quality” as a safety and hygiene factor, which is one characteristic that differentiates it from other sectors. The purpose of this paper is to examine how the food industry sector's characteristics affects its adoption of Lean Six Sigma (LSS) practices and performance improvement. A survey of 145 food industry firms was conducted and then analyzed using structural equation modeling to test the research framework. Our findings suggest that LSS is relevant and effective in this sector. Food industry performance is positively affected by the adoption of LSS practices. Moreover the adoption of LSS practices in the food industry is greatly affected by the level of experience of the individual company. The level of experience moderates two performance indicators very valued by the sector (financial gains and product quality). The food industry is to a certain extent affected by the sector's characteristics. The compulsory cleaning practices restrict adoption of LSS practices such as set-up time reduction. Six Sigma role structure and Statistical Process Control dimensions are among the sector's least adopted practices. These practices require financial resources for training, which can be a challenge in a sector with low margins that primarily focuses on cost reduction, and they require statistical techniques and knowledge that is generally considered complex and too advanced in the food industry. These findings suggest that as managerial awareness of the relevance of LSS practices to food industry performance improvement increases, that managers will encourage employees to gain experience using the tools.

Updated Technique for Reliable, Easy, and Tolerated Transcranial Electrical Stimulation Including Transcranial Direct Current Stimulation.

Transcranial direct current stimulation (tDCS) is a noninvasive method of neuromodulation using low-intensity direct electrical currents. This method of brain stimulation presents several potential advantages compared to other techniques, as it is noninvasive, cost-effective, broadly deployable, and well-tolerated provided proper equipment and protocols are administered. Even though tDCS is apparently simple to perform, correct administration of the tDCS session, especially the electrode positioning and preparation, is vital for ensuring reproducibility and tolerability. The electrode positioning and preparation steps are traditionally also the most time consuming and error-prone. To address these challenges, modern tDCS techniques, using fixed-position headgear and pre-assembled sponge electrodes, reduce complexity and setup time while also ensuring that the electrodes are consistently placed as intended. These modern tDCS methods present advantages for research, clinic, and remote-supervised (at home) settings. This article provides a comprehensive step-by-step guide for administering a tDCS session using fixed-position headgear and pre-assembled sponge electrodes. This guide demonstrates tDCS using commonly applied montages intended for motor cortex and dorsolateral prefrontal cortex (DLPFC) stimulation. As described, selection of the head size and montage-specific headgear automates electrode positioning. Fully assembled pre-saturated snap-electrodes are simply affixed to the set position snap-connectors on the headgear. The modern tDCS method is shown to reduce setup time and reduce errors for both novice and expert operators. The methods outlined in this article can be adapted to different applications of tDCS as well as other forms of transcranial electrical stimulation (tES) such as transcranial alternating current stimulation (tACS) and transcranial random noise stimulation (tRNS). However, since tES is application specific, as appropriate, any methods recipe is customized to accommodate subject, indication, environment, and outcome specific features.

Setup time reduction to enhance the agility of the manufacturing industry through kobetsu kaizen and SMED: a case study

Setup time reduction to enhance the agility of the manufacturing industry through kobetsu kaizen and SMED: a case study

Evaluation Setup Process on Rotogravure Printing Machine in Oder to Reduce Setup Time

The company carries out various ways to be able to meet customer demand quickly, one of which is to speed up the production process. In the printing process, the company encountered a problem, one of which was the high downtime caused by the setup process. The standard setup time determined by the company is 150 minutes but in fact the time required is 211.33 minutes. This shows that there are inefficient methods applied by the company. In this study, we will evaluate the work method to get errors so that the setup duration becomes high. This study will draw on the Modified Cooper Harper Scale and Single Minute Exchange of Dies (MCH-SMED) method to balance the workload between operators so that the setup time can be reduced. The MCH method is used to analyze the mental and physical workload on an operator based on a tree decision scale so that it can balance the workload between operators. SMED is used to identify on-line and off-line operations in the setup process. This study aims to produce a comparison of the standard setup times that have been set by the company and after evaluating the integration process of printing machine setup (MCH-SMED). The results of this study are to obtain a new sequence of operations that can reduce the duration of setup time to 143.19 minutes or be able to reduce the setup time by 32%

TRIZ and Lean Philosophies Applied Together in Management Activities

Purpose: In the current market, the Portuguese industry faces strong competition from countries with substantially lower operating costs. The agri-food industry is also subject to increasing competition, both nationally and internationally. The utilization of methodologies that, in addition to continuous improvement, provide the development of creative and innovative solutions may be relevant for highlighting and differentiating between organizations. In this work, Teoriya Resheniya Izobretatelskikh Zadach and Lean Philosophies have been implemented together. Methodologies as Matrix of Ideality Matrix of Contradiction, Single Minute Exchange of Die, 5S and the Substance-Field analyses were used as complementary tools to improve the production management activities of agri-food sector. Strongly focused on the issues of time wastage and the organization and management of the filling line, the implementation of these methodologies led to a reduction of setup times, of the operators’ movement and an improvement in the line’s management and organization, and improve the results of 5S audits, depending on the work station. The aims of this study is the implementation of diferent methodologies, philosophies and tools to improve management activities.Methodology/Approach: The methodology presented in this work involves using Lean and TRIZ methodologies together. Namely Matrix of Ideality, the Matrix of Contradictions, SMED, 5S and the Substance-Field Analysis, were used to optimize the management activities, in agro-food industrial sector. The methodology strongly focused on the issues of time wastage, organization and management of an filling line.Findings: The implementation of methodologies led to a reduction of setup times by 60% to 70%, a reduction of the operators’ movement during format changes by 26.2%, and an improvement in the line’s management and organization by 9% to 12%, depending on the work station.Research Limitation/implication: In the management activities, the results are not universal. Therefore, the same methodology applied in another industrial sector will present differents results. Nevertheless, the application of this methodology and the tools choosen only make sense if it facilitates the management of improvements.Originality/Value of paper: There is a need and demand for innovative solutions that lead to continuous improvement, production processes optimization and resource saving. The combination of different validated methologies, with new concrete studies, is always in scientific and technical interest and continuously sought-after (demanded, welcome) by academic and industrial sectors.

Reducing Process Setup in a Smart TV Card Factory

Companies are looking for new ways to carry out their processes automatically and accurately. Thus, the machines that are part of the process need to be stopped, called setup, so that they are prepared to continue producing other products on the production line. This work was developed with the main objective of showing the effect of reducing the setup time in a television factory, and as specific objectives to present the concept of Fast Tool Change; present the negative effects of a production that has a lengthy setup; punctuate the benefits of reducing setup time in a factory. The methodology used is focused on exploratory research where it was necessary to visit the production line of a 32 ", 42", 50 "and 55" Smart TV board manufacturing company, in order to apply the data collection instruments. To verify the failures resulting from the shutdowns and the problems that are related to the production setup time, quality tools such as Ishikawa Diagram, 5W2H and before and after study flowchart were used. As expected results, the company was able to reduce machine preparation delays, batch delays became minimal.

Surgical Instrument Optimization to Reduce Instrument Processing and Operating Room Setup Time.

As health care expenditures rise, novel ways to increase efficiency are sought. The operating room (OR) represents an area where there is opportunity to optimize work flow and supply use. Evidence suggests that instrument redundancy in the OR tends to be high and that direct cost savings can be achieved by "optimizing" surgical trays. The purpose of this study was to quantify the potential time savings associated with surgical tray optimization. Instrument utilization was reviewed for 4 procedures: tonsillectomy, sinus surgery, septoplasty, and septorhinoplasty. Instruments used in <20% of cases were excluded. Data on tray assembly time in the central processing department and instrument setup time in the OR were prospectively collected over a 3-month period before and after tray optimization. Student's t test (α = 0.05) was used to determine whether times were significantly different following optimization. Tray assembly times were found to be significantly shorter following optimization, with percentage reduction in time ranging from 58% to 66% (P < .05). In the OR, percentage reduction in setup time ranged from 26% to 37% (P < .05). Variability in assembly and setup times was also found to be narrower postoptimization. Tray optimization may reduce stress and adverse events and allow managers to better estimate staffing requirements. Cost-benefits could not be determined given a limited understanding of how departments choose to redistribute time savings. Measurable and significant time savings can be achieved by assessing instrument utilization rates and reducing tray redundancy, leading to lower performance variability and improved efficiency.

PERANCANGAN MEJA PUTAR ROLL WELDING SEBAGAI ALAT BANTU PENGELASAN (STUDI KASUS : ART WELDING PT. MECO INOXPRIMA)

Welding that produces a quality connection and is very possible to connect metal by welding in various shapes and positions. Therefore the welding process must require a practical material supporting device and in accordance with the needs of all welding positions which will facilitate and provide welder comfort in welding. So that the results of maximum and quality welds (good hasis las visually) are produced in this study the type of connection used is angular joints with the aim of designing and making tools to get the results of welding joints and comparing the distortions that occur between using desk tools rotate and without using tools. In this study Gtaw welding was used with the brand DC ARC WELDER with type Bz-300F-3 and filler type ER 308L, Voltage 20-30 V, travel speed 60 mm / min and variations of Flow (A) namely 100 A, 125 A and 150 A. with a diameter of 2.4 mm as a filler. The study was limited to the design and manufacture of tools and measurements of distortion carried out 20 times. Distortion measurement uses a dial indicator with a starting point / zero point on the end of the test object and the end point in the weld joint area. The results show that the use of roll welding tools can reduce the occurrence of distortion. The smallest value of distortion is obtained using a roll welding rotary table tool which is equal to 0.33 degrees, while the smallest value of distortion without using roll welding is 1.33 degrees. And the use of roll welding rotary table aids can reduce welding defects reduce setup time and can increase production volume which results in a decrease in production costs, making it quite feasible and efficient in terms of the economy.

Focus on test, measurement, and analytical equipment

Focus on test, measurement, and analytical equipment

Application of SMED Methodology and Scheduling in High-Mix Low Volume Production Model to Reduce Setup Time: A Case of S Company

Nowadays rapid changes in consumer demand determines the production model. The demand for “single and large quantity” products has gradually turned into a “high-mix and low volume” product demand. The main problem of high-mix low volume model is significantly increasing frequency of set up, causing an increase in set-up time for production. For set-up reduction strategies, Shingo (1985) proposed single minute exchange of die (SMED) methodology. The SMED methodology makes it possible to reduce setup (changeover) operations time within 10 minutes. Therefore, in this study take a cable processing company as a case for improvement. The potential of faster setup cannot be completely achieved with SMED method. So, in this paper, it also provides an optimized scheduling reference indicator for the molding machine that decision makers to determine the sequencing rule of scheduling by each criterion through the system to achieve maximum benefit for company.

Design and validation of two embodied mirroring setups for interactive games with autistic children using the NAO humanoid robot.

Socially assistive robots have shown potential benefits in therapy of child and elderly patients with social and cognitive deficits. In particular, for autistic children, humanoid robots could enhance engagement and attention, thanks to their simplified toy-like appearance and the reduced set of possible movements and expressions. The recent focus on autism-related motor impairments has increased the interest on developing new robotic tools aimed at improving not only the social capabilities but also the motor skills of autistic children. To this purpose, we have designed two embodied mirroring setups using the NAO humanoid robot. Two different tracking systems were used and compared: Inertial Measurement Units and the Microsoft Kinect, a marker-less vision based system. Both platforms were able to mirror upper limb basic movements of two healthy subjects, an adult and a child. However, despite the lower accuracy, the Kinect-based setup was chosen as the best candidate for embodied mirroring in autism treatment, thanks to the lower intrusiveness and reduced setup time. A prototype of an interactive mirroring game was developed and successfully tested with the Kinect-based platform, paving the way to the development of a versatile and powerful tool for clinical use with autistic children.

MINIMALISASI BIAYA SIMPAN DAN BIAYA SETUP PADA MULTIPLE PRODUK: SIMULASI DENGAN CAPACITATED LOT SIZING PROBLEM

Lot sizing problem in production planning aims to optimize production costs (processing, setup and holding cost) by fulfilling demand and resources capacity costraint. The Capacitated Lot sizing Problem (CLSP) model aims to balance the setup costs and inventory costs to obtain optimal total costs. The object of this study was a plastic component manufacturing company. This study use CLSP model, considering process costs, holding costs and setup costs, by calculating product cycle and setup time. The constraint of this model is the production time capacity and the storage capacity of the finished product. CLSP can reduce the total production cost by 4.05% and can reduce setup time by 46.75%. &#x0D; Keyword: Lot size, CLSP, Total production cost.

Fast, Low-Dose Megavoltage-Topogram Localization on TomoTherapy: Initial Clinical Experience With Mesothelioma Patients

PurposeThis study aimed to evaluate the potential of megavoltage-topogram (MV-topogram)–based alignment as an alternative to megavoltage computed tomography (MVCT) in reducing setup time and imaging dose for patients with malignant pleural mesothelioma who are receiving TomoTherapy. Methods and MaterialsTwelve patients were enrolled in an ongoing institutional review board approved clinical trial at our institute. Patients were set up with a clinical protocol using red lasers. Anteroposterior (AP) and lateral (LAT) MV-topograms were acquired using gantry angles of 0°/90° with a 1 mm collimator opening, all multileaf collimator leaves open, a couch speed of 4 cm/s, and a 12.5-second scanning time. Routine MVCT scans were performed immediately afterward. The MV-topograms were reconstructed and enhanced using contrast-limited adaptive histogram equalization. Anteroposterior and LAT kilovoltage digital reconstructed topogram images were reconstructed based on TomoTherapy geometry from computed tomography simulation scans. Registrations between MV-topograms and kilovoltage-digital reconstructed topogram images were performed manually, and patients’ daily shifts were recorded. Results were compared against the corresponding daily MVCT shifts. MV-topogram and MVCT doses were measured and recorded using an ion chamber on a cheese phantom with depths between 1 and 14 cm, as well as the times required to acquire the 2 image modalities. ResultsThe mean and standard deviation of shift discrepancies between MV-topogram and MVCT were 0.74 ± 2.08, –0.09 ± 4.46, and 0.45 ± 3.57 mm in the LAT, longitudinal, and vertical directions, respectively. The MVCT imaging doses measured were 14.74 to 26.92 times higher than the MV-topogram doses, depending on depth. On average, MV-topograms with a mean scan length of 50 cm achieved a 5-fold image acquisition time savings over MVCT, with a mean scan length of 38 cm. ConclusionsMV-topograms has the potential to provide alignment performance equivalent to that of MVCT for patients with mesothelioma, with a significant reduction in imaging dose and acquisition time.

Experimental Study of Setup Time Reduction in CNC Machine Shop

Experimental Study of Setup Time Reduction in CNC Machine Shop

A Two-Echelon Supply Chain Management With Setup Time and Cost Reduction, Quality Improvement and Variable Production Rate

This model investigates the variable production cost for a production house; under a two-echelon supply chain management where a single vendor and multi-retailers are involved. This production system goes through a long run system and generates an out-of-control state due to different issues and produces defective items. This model considers the reduction of the defective rate and setup cost through investment. A discrete investment for setup cost reduction and a continuous investment is considered to reduce the defective rate and to increase the quality of products. Setup and processing time are dependent on lead time in this model. The model is solved analytically to find the optimal values of the production rate, safety factors, optimum quantity, lead time length, investment for setup cost reduction, and the probability of the production process going out-of-control. An efficient algorithm is constructed to find the optimal solution numerically and sensitivity analysis is given to show the impact of different parameters. A case study and different cases are also given to validate the model.

Tattoo free setup for partial breast irradiation: A feasibility study.

PurposePatients undergoing external beam accelerated partial breast irradiation (APBI) receive permanent tattoos to aid with daily setup alignment and verification. With the advent of three‐dimensional (3D) body surface imaging and two‐dimensional (2D) x‐ray imaging‐based matching to surgical clips, tattoos may not be necessary to ensure setup accuracy. We compared the accuracy of conventional tattoo‐based setups to a patient setup without tattoos.Materials/methodsTwenty consecutive patients receiving APBI at our institution from July 10, 2017 to February 13, 2018 were identified. All patients received tattoos per standard of care. Ten patients underwent setup using tattoos for initial positioning followed by surface imaging and 2D matching of surgical clips. The other ten patients underwent positioning using surface imaging followed by 2D matching without reference to tattoos. Overall setup time and orthogonal x‐ray‐based shifts after surface imaging per fraction were recorded. Shift data were used to calculate systematic and random error.ResultsAmong ten patients in the “no tattoo” group, the average setup time per fraction was 6.83 min vs 8.03 min in the tattoo cohort (P < 0.01). Mean 3D vector shifts for patients in the “no tattoo” group were 4.6 vs 5.9 mm in the “tattoo” cohort (P = NS). Mean systematic errors in the “no tattoo” group were: 1.2 mm (1.5 mm SD) superior/inferior, 0.5 mm (1.6 mm SD) right/left, and 2.3 mm (1.9 mm SD) anterior/posterior directions. Mean systematic errors in the “tattoo” group were: 0.8 mm (2.2 mm SD) superior/inferior, 0.3 mm (2.5 mm SD) right/left, and 1.4 mm (4.4 mm SD) anterior/posterior directions. The random errors in the “no tattoo” group ranged from 0.6 to 0.7 mm vs 1.2 to 1.7 mm in the “tattoo” group.ConclusionsUsing both surface imaging and 2D matching to surgical clips provides excellent accuracy in APBI patient alignment and setup verification with reduced setup time relative to the tattoo cohort. Skin‐based tattoos may no longer be warranted for patients receiving external beam APBI.

Redução do tempo de setup por meio da técnica single minute exchange of die em empresa do setor de linha branca

O artigo apresenta a redução do tempo de setup por meio da aplicação da técnica Single Minute Exchange of Die (SMED), em uma empresa do setor de linha branca. A pesquisa foi desenvolvida por meio de entrevistas aos funcionários e acesso aos dados de produção, extraídos do sistema informatizado a empresa. O estudo de caso avaliou as atividades do setup da prensa do setor de estamparia de uma linha de montagem de fogões. Os resultados da pesquisa mostram as fases de implantação da técnica SMED, com avaliação das atividades de setup interno e setup externo; a conversão de setup interno em externo, e a padronização das atividades de preparação, as quais foram executadas como setup externo. Os ganhos obtidos com a redução do tempo de setup comprovam o uso da técnica SMED na melhoria da eficiência e aumento da capacidade produtiva.

A Compliant Transoral Surgical Robotic System Based on a Parallel Flexible Mechanism.

Transoral robotic surgery (TORS) allows for access to oropharyngeal regions in an effective and minimally invasive manner. However, safe TORS access to deep pharyngeal (such as hypopharynx) sites remains a great challenge for current surgical robotic systems. In this work, we introduce a novel continuum robot with an optimized flexible parallel mechanism, to meet stringent requirements imposed by TORS on size, workspace, flexibility, and compliance. The system is comprised of two parts, a guidance part and an execution part, and achieves 11 controllable degrees of freedom. The execution part of the robot, based on the optimized flexible parallel mechanism, is able to reach deep sites in the oropharynx and larynx with the assistance of the continuum guidance part. In addition to the mechanical design, extensive analysis and experiments were carried out. Kinematic models were derived and the reachable workspace of the robot was verified to cover the entire target surgical area. Experimental results indicate that the robot achieves significantly enhanced compliance. Additionally, the designed robot can withstand a load of 1.5N within the allowable range of the deflection. The positioning errors caused by the interference between different mechanisms can be effectively eliminated using the proposed compensation method. The maximum displacement error of this system under various conditions is less than 2mm and the maximum bending error is less than 7.5°, which are satisfied for TORS. Cadaver trials were conducted to further demonstrate the feasibility. The reduced setup time and the reduced time to access the target site indicate that the developed surgical robotic system can achieve better operative efficiency in TORS when compared with current systems.

Application of Lean methodologies in the reduction of setup times in the pharmaceutical industry

Introduction: The strong international competitiveness motivated by globalization with the purpose of reaching an increasingly demanding public, makes cost reduction and quality increase a primary need across all sectors. The generic drug industry where price is the primary weapon in consumer reach is no exception and creates a strong need in the application of Lean methodologies to optimize the production. Objectives: Reduce of changeover times by the application of lean methodologies structured by a proposed model. Methods: This study started with a review of the bibliography of the Lean’s origin and the several methodologies ending with the application of a proposed application model. The implementation was based on a detailed study of the setups resulting in a set of solution proposals dedicated to the main problems applying several lean tools. Results: Reduction of change times by 20% and waiting times by 24.5% within 3 months. Conclusions: The application of Lean methodologies revealed a great utility in the identification of causes and in the creation of solutions. The implementation of this model, although in an initial phase, allowed not only reduction of the times of changes, but also other improvements such as the reduction of the number of waits. However, this application, due to being inserted in the pharmaceutical industry, is limited by some procedures that cannot be changed.