Setup Time Reduction Research Articles

A proposed approach for setup time reduction through integrating conventional SMED method with multiple criteria decision-making techniques

Short setup time is an essential element for the effective implementation of many lean pillars, i.e., JIT, and Kanban. Most of the current setup reduction methodologies are based on Shingo’s Single Minute Exchange of Dies (SMED) that suggests the conversion of internal setup operations to external operations. However, the conventional SMED approach – as proposed by Shingo – does not possess a systematic approach to accomplish this conversion. Thus, a new approach is proposed in order to aid the process engineers in implementing SMED. The proposed approach is based on the conventional SMED, but also it incorporates Multiple Criteria Decision-Making Techniques (MCDM) to the third implementation phase. The MCDM techniques used in this work are Analytical Hierarchal Process (AHP), Preference Selection Index (PSI) and Technique for Order Preference by Similarity to Ideal Solution (TOPSIS). The proposed approach provides a systematic procedure for selecting the best setup technique among the available alternatives, and takes also into consideration other factors that affect the decision-making process; including: cost, energy, facility layout, safety, life, quality and maintenance. A real example of PVC industry is used to exemplify the approach. The results demonstrate the capability of the proposed approach in setup time reduction, which in turn will improve machines’ utilization, and increase the productivity and flexibility of the whole facility.

Single-Use Instruments, Cutting Blocks, and Trials Increase Efficiency in the Operating Room During Total Knee Arthroplasty: A Prospective Comparison of Navigated and Non-Navigated Cases

The purpose of this prospective controlled trial was to determine if efficiency increases could be achieved in non-navigated and navigated total knee arthroplasties by replacing traditional saws, cutting blocks, and trials with specialized saws and single-use cutting blocks and trials. Various timing metrics during total knee arthroplasty, including operating room preparation times and specific intra-operative times, were measured in 400 procedures performed by eight different surgeons at 6 institutions. Efficiency increases were the result of statistically significant reductions in combined instrument setup and cleanup times as well as in adjusted surgical episode times in navigated total knee arthroplasties. Single-use instruments show promising benefits, but adequate patient follow-up is needed to confirm safety and efficacy before they can be widely adopted. Nevertheless, the authors believe that the use of single-use instruments, cutting guides, and trial implants for total knee arthroplasty will play an increasing role in improving operating room efficiency.

Research on Five-Axis CNC Machining Simulation and Experiment of Integrated Impeller Based on VERICUT

Machining with five-axis equipment can offer manufactures many advantages, including dramatically reduced setup times, lower costs per part, more accurate machining and improved part quality. While in five-axis machining, the tool axis changes frequently, even the most experienced engineers are difficult to judge the correctness of its tool path. So in this paper, taking five-axis machine tools as the prototype, the process of building NC simulation platform was introduced by using simulation software VERICUT. After that, it introduced simulation operations, verifying the simulation platform and data simulation function. Finally, the correctness of the simulation was verified by machining experiments. Researching CNC machining process on the VERICUT platform, the research results were used in five-axis machining simulation of integrated impeller and it improved both the process capacity and efficiency of the integrated impeller greatly. This method obtained in this paper could eliminate the colliding and interference phenomenon during test cut, reduce costs, improve the efficiency of programming and shorten the manufacturing period.

Shortening cycle times in multi-product, capacitated production environments through quality level improvements and setup reduction

This paper addresses the issue of investing in reduced setup times and defect rates for a manufacturer of several products operating in a JIT environment. Production cycle times can be shortened by investing in setup time and defect rate reductions, respectively. The objective is to determine optimal levels of setup time and defect rate reductions along with the corresponding optimal levels of investments respectively, and the optimal production cycle time for each product. The problem is constrained by demand requirements, process improvement budget limitations, and manufacturing and warehousing capacity constraints. We consider the cases of product-specific quality improvements and joint-product quality improvements. A general nonlinear optimization models of these problems are formulated. A convex geometric programming approximation of these models is developed respectively, in order to solve them. The approximation can be made to any desired degree of accuracy. Our empirical findings provide insights into a number of managerial issues surrounding investment decisions in product-specific quality improvements and setup reductions due to a product redesign as well as in joint-product improvements due to a process redesign.

Improving Changeover Time: A Tailored SMED Approach for Welding Cells

Short changeover times have always been critical in manufacturing business. Set-up duration reduction initiatives have been associated with Shingós ‘Single Minute Exchange of Die’ (SMED) method. Although a great number of companies have initiated SMED, some failed on implementation. The main reason is that strict application of Shingós SMED methodology is not the most efficient way to reduce set-up times in all situations. In the present study a tailored methodology is presented that has been developed specifically for an automotive supplier. The validation of the proposed method was done through implementation on an industrial welding cell for a period of four months. The main finding is that in addition to SMED tailored methodology, appropriate strategy definition and preparatory activities are key enablers for success. That includes project targets and timescale definition, selection of the appropriate team and coordinator, allocation of specific roles and responsibilities to each team member, training of team and shop floor staff on the new methodology and changeover standards. By implementing the new tailored SMED improvement programme, the company achieved 33% reduction on changeover time.

Applying Lean Manufacturing Tool (SMED/QCO) to Overcome Additional Investment for Meeting Customer Needs – A Study at Robert Bosch (I) Limited

Nowadays the market is increasingly demanding more customized products, thus making the manufacturers under the pressure of cost reduction, to survive in the highly competitive market. Working on this, Robert Bosch INdia (RBIN) Limited, Bangalore Plant (BanP) designs and produces Diesel systems which make vehicles more cleaner and economical. To be the world’s leading manufacturer of diesel injection systems, Bosch has to manufacture its very own design to fulfill the requirements for every customers, economically. Fuel Injection Equipment in diesel engine is the “Heart of the Engine” and plays a major role in its performance, emissions and reliability. Hot Forged Rail (HFR) finds its application in common rail fuel injection system, which stores the fuel at high pressure (1600bar). And at the same time, the pressure oscillation, which is generated due to the high pressure pump delivery and the injection of fuel are damped by the rail volume. Its design varies according to customer requirement and engine design. Therefore, BanP has to produce different types of rails to complete diesel market in India. In order to be customer centric and productive, BOSCH follows Bosch Production Systems (BPS), the elements of BPS in Lean manufacturing are Value Stream Mapping (VSM), Value Stream Design (VSD) and Value Stream Planning (VSP). The Single Minute Exchange of Die (SMED) is one important lean manufacturing tool to reduce waste and improve production flexibility, allowing lot size reduction and manufacturing flow improvements. Quick Change Over (QCO) is a set of activities (preparation, changing and adjustment) which are being carried out in between the production of two varieties to reduce changeover time and to reach the optimum production running. The proposed SMED approach was tested for injection machines changeovers in the automotive industry and the implementation had enabled reduction in setup time, through company’s internal resources reorganizations without the need for significant investment. The objective of the present study is to implement the SMED/QCO tool approach in RBIN, BanP, HFR production line to reduce the changeover time by >65% and improve availability by 15%, thereby eliminating the possibility of investing on new production line to meet customer demand.

Lean manufacturing performance in Indian manufacturing plants

Purpose – The purpose of this paper is to examine the current state of lean adoption in Indian manufacturing plants and its impact on operational performance.Design/methodology/approach – A survey questionnaire was developed and adapted based on work done in US industries. The survey questionnaire was sent to 400 firms in four geographic regions in India. In total, 79 usable responses were received for the study.Findings – Since lean manufacturing is a multi‐dimensional construct, the results demonstrate that approximately 80 percent of the respondents have implemented many dimensions of lean – focus on customer needs, pull system, setup time reduction, total productive maintenance, supplier performance, statistical process control, and cross‐departmental problem solving. The operational metrics have improved on all accounts: high productivity, reduced lead time, improved first‐pass correct output, reduced inventory and space requirement. Interestingly, respondents have indicated that first‐pass correct o...

External Setup in SMED Improvement in an Injection Molding Manufacturing Company

The purpose of the paper is to determine the applicability of external setup preparation activities of Single Minute Exchange of Die (SMED) in reducing setup time. Improving the external setup preparation of SMED leads a better and effective working performance. To improve the effectiveness of the external setup in SMED, it is concerned particularly with changing the internal activities into external activities and improving the current external activities. The process failure mode and effect analysis (PFMEA) adopted to analyze the problem faced of external set up process.The verification of the methods is done by an application a plastic injection molding manufacturing process where setup times are critical for time reduction.

Improved Localization Accuracy in Magnetic Source Imaging Using a 3-D Laser Scanner

Brain source localization accuracy in magnetoencephalography (MEG) requires accuracy in both digitizing anatomical landmarks and coregistering to anatomical magnetic resonance images (MRI). We compared the source localization accuracy and MEG-MRI coregistration accuracy of two head digitization systems-a laser scanner and the current standard electromagnetic digitization system (Polhemus)-using a calibrated phantom and human data. When compared using the calibrated phantom, surface and source localization accuracy for data acquired with the laser scanner improved over the Polhemus by 141% and 132%, respectively. Laser scan digitization reduced MEG source localization error by 1.38mm on average. In human participants, a laser scan of the face generated a 1000-fold more points per unit time than the Polhemus head digitization. An automated surface-matching algorithm improved the accuracy of MEG-MRI coregistration over the equivalent manual procedure. Simulations showed that the laser scan coverage could be reduced to an area around the eyes only while maintaining coregistration accuracy, suggesting that acquisition time can be substantially reduced. Our results show that the laser scanner can both reduce setup time and improve localization accuracy, in comparison to the Polhemus digitization system.

PCE-based fast path control in multi-domain photonic networks

We discuss issues for controlling an optical path in large-scale photonic networks, and introduce an inter-domain path control system based on Path Computation Elements (PCEs). In the system, maximum flow information enables the load balancing of traffic, and Path Key scheme preserve the confidentiality of internal topology information among carrier networks. Based on the experimental results, we show the path setup in the introduced system is significantly faster than the manual path setup among domains in current carriers' networks. For the additional reduction of the path setup time, we propose the domain-wise paralleled signaling method. We also show that decreasing the number of nodes per domain makes path setup faster in the introduced system with deployment of the proposed signaling method.

An approach for developing a schemaless XML dataspace profiling system

Dataspace systems have been proposed recently as an alternative to the traditional data integration approach. They offer reduced setup time and costs by allowing cooperation among the data sources based on the knowledge gained gradually through user interaction. A dataspace is a collection of heterogeneous and beforehand unfamiliar but interrelated data sources. In this article, we consider dataspaces composed of XML-based data sources. The XML query and analysis systems designed to satisfy the user’s sophisticated information needs presuppose that they are familiar with the contents, structures and semantics of the underlying data sources. In order to provide this information, we introduce and specify a schemaless XML dataspace profiling system that assists the user in selecting data sources relevant to him/her and in validating their consistency by detecting the potential data conflicts among them. We also demonstrate how our approach affords the possibility of utilizing an advanced XML query system.

Reducing Setup Time in Manufacturing Cells in a JIT Environment

Setup time is a major issue in Just-in-time environments. Even with a cellular manufacturing configuration, reduction of setup time is not fully insured and needs to be explicitly targeted. We have introduced a mathematical programming model which would reduce sequence-dependent setup time in manufacturing cells. Since the BIP model is NP hard, a solution approach based on a Genetic Algorithm has been improvised.

Determination of the relative position between grinding wheel and a cylindrical workpiece on a 7 axis grinding machine by acoustic emission

The contact between grinding wheel and workpiece in the grinding process is recognized by acoustic emission (AE). Two acoustic emission monitoring systems (MS) were integrated into a 3 axis CNC grinding machine. A laptop allows the signal acquisition and visualization. The acquired AERMS signals from the contact between tool and workpiece are analyzed permitting to establish the most suitable AE monitoring system to recognize the contact in a particular grinding machine. In a second experimental setup the selected MS was installed on a 7 axis tool grinding machine at an industrial partner. At this partner, the relative position between grinding wheel and workpiece was previously determined manually. This procedure has a direct influence on the results depending on the technical skills of the operator. The automation of this activity supported by acoustic emission has led to satisfactory results regarding the relative position between grinding wheel and workpiece and contributed to the setup time reduction.

Lean production supply chain management as driver towards enhancing product quality and business performance

PurposeThe purpose of this paper is to obtain a better understanding of the extent to which lean production permeates manufacturing companies in Malaysia by drawing on supply chain management (SCM) managers' or production managers' perception of lean production practices and level of performances in the industry.Design/methodology/approachThe instrument used in this study is a structured survey questionnaire consisting of two major parts. The first part comprises several variables measuring lean production practices, and the second part consists of several performance measurements. Sample companies are chosen from Malaysian manufacturing companies listed in the Federation of Malaysian Manufacturers directory. From the 300 companies sampled, 200 responses were completed, representing a 67 per cent response rate.FindingsThe results support the conceptual model, demonstrating strong association between lean production, product quality performance, and business performance. The structural equation modelling (SEM) results reveal that “reduced setup time” appears to be of primary importance in the linkage between lean production, product quality performance and business performance. It is also instructive, from a score of 67.21 on the Malaysian Lean Production Index (MLPI), that manufacturing companies in Malaysia must marshal their effort to implement a more effective lean production SCM in order to improve on product quality performance and business performance.Practical implicationsThis research adds to the body of knowledge on lean production SCM in manufacturing industry. This paper may be of particular interest to practicing production managers, or SCM managers, as it suggests what factors should be emphasized in lean production.Originality/valueThe originality of this paper lies within the context in which this study is undertaken as it seeks to address key relationships between lean production, product quality performance and business performance within the Malaysian manufacturing industry, where relatively few studies are available. In addition, relationships between constructs are analyzed through SEM that measures not only magnitude but also the causal direction of the relationships.

Implementation of the scanning laser Doppler vibrometer combined with a light-weight pneumatic artificial muscle actuator for the modal analysis of a civil structure

The identification of the modal parameters of bridges and other large civil constructions has become an important research issue. Different approaches have been proposed depending on the excitation used: ambient excitations (due to wind, traffic, ... )o r artificial excitations (e.g. impact test with heavy drop weights). In practice it turns out that not all modes are well excited by the ambient forces. Hence the application of an artificial actuator is advisable. The problem is that larger constructions often require large and heavy excitation devices, which are hard to manipulate. Another difficulty encountered in performing a modal analysis on large civil constructions is the necessity for a large number of high sensitivity sensors. Consequently a large number of cables has to be installed resulting in a large setup time. Thispaperisaproof-of-conceptwhichdemonstratesthepossibilityofusinglightweightPneumaticArtificialMusclescombined with the scanning laser Doppler vibrometer to perform a modal analysis on a civil structure. This combination allows for an important reduction in setup time and allows for sine testing as well as the application of broadband signals such as periodic chirps, true noise or multisines.

Implementation of the Scanning Laser Doppler Vibrometer Combined with a Light-Weight Pneumatic Artificial Muscle Actuator for the Modal Analysis of a Civil Structure

The identification of the modal parameters of bridges and other large civil constructions has become an important research issue. Different approaches have been proposed depending on the excitation used: ambient excitations (due to wind, traffic, …) or artificial excitations (e.g. impact test with heavy drop weights). In practice it turns out that not all modes are well excited by the ambient forces. Hence the application of an artificial actuator is advisable. The problem is that larger constructions often require large and heavy excitation devices, which are hard to manipulate. Another difficulty encountered in performing a modal analysis on large civil constructions is the necessity for a large number of high sensitivity sensors. Consequently a large number of cables has to be installed resulting in a large setup time.This paper is a proof-of-concept which demonstrates the possibility of using lightweight Pneumatic Artificial Muscles combined with the scanning laser Doppler vibrometer to perform a modal analysis on a civil structure. This combination allows for an important reduction in setup time and allows for sine testing as well as the application of broadband signals such as periodic chirps, true noise or multisines.

Cost efficient mass customisation with a web-based manufacturing execution system

Manufacturing execution systems (MES), which allow a continuous flow of information between the systems that are part of the production process, are used in the manufacturing industry among other things as a means to facilitate mass customisation, i.e., a tremendous increase in variety and customisation without a corresponding increase in costs. Using the case of MR-CM®, an MES developed and implemented by the Maschinenfabrik Reinhausen, the function of an MES when put into practice as well as the benefit potential released in this case will be illustrated. Gains in productivity were mainly achieved by reducing setup times, which in turn led to reduced production cost and increased production flexibility. Tool inventories were reduced, and thus also the expenses of capital tied up in tools. Further advantages of MES are increasing production transparency, improved capacity utilisation and process reliability.

Multi-Robot Approach for Automation of an Industrial Profile Lamination Process

In this paper we present a multi-robot application from the field of industrial automation. The multi-robot system forms the central part of a novel kind of profile wrapping machine, which is used to laminate decorative surfaces onto profiles, e.g. parts for window frames. The robots operate in a confined area and perform different tasks such as re-tooling and setting up machine parts simultaneously as quick and as accurate as possible. During lamination, each robot uses a special roller to press the adhesive-coated surface onto the profile. For this application, we use a scalable number of at least 10 and up to 50 standard articulated-arm robots. The system consists of three lines of robots, three movable depots capable of holding hundreds of different rollers and a computer with a fieldbus interface allowing for communication with additional machine components like servo converters. On the computer runs custom software and serves as a central control unit. The control software receives the given reference values, like roller positions and desired pressure, and distributes them to the robots. Robot actions are triggered, monitored and synchronized by the central control unit, but every robot performs its tasks autonomously. The main control unit and robots communicate via standard Ethernet, since time-critical actions can be handled on each robot's own controller. User interface and sophisticated software modules allowing for a completely automated machine configuration are also linked to the control system via Ethernet, as well as any additional components like data logging or remote service applications. Tests revealed that the multi-robot approach for profile wrapping reduces set-up time from more than 1.5hrs on conventional machines to approximately five minutes. At the same time, it ensures a higher and more constant process quality as the system autonomously compensates for wear of rollers or variation in the profile's geometry.

A cost-based model for customer batching in mass service operations

Customers of mass services have similar needs. Therefore, operations managers have options to process customers in batches, rather than individually. While batching in manufacturing may reduce setup time, batching in services may reduce both setup and processing time. Although substantial prior research has been done on batch sizes in the manufacturing context, significant differences in cost structures complicate direct application of these models to services. Of special concern for polices regarding batching in service operations are immediate temporal effects on and preferences of customers. This paper synthesizes and extends previous research to develop and analyze an economic model for determining optimal batch sizes for many mass service scenarios.

Mobile mapping system for the automated detection and analysis of road delineation

This study will explore a low-cost mobile mapping system that has been developed to carry out road delineation surveys. This data acquisition system has been designed to be fully compatible for both mounting and calibration on any vehicle possessing a set of standard roof bars. This system, constructed inside a standard roof box, is fully self-contained and powered making it completely independent from the carrier vehicle. In order to allow ease of use by both field engineers and untrained personnel, user-friendliness was prominent in the design of both the hardware and the user interface. Simplified calibration procedures reduce set-up times and again allow untrained personnel to initialise the hardware. Two applications have been developed for this system. Automated raised pavement marker detection allows for the mapping of both functioning and non-functioning road studs using stereo reconstruction coupled with navigation data. A road line detection algorithm has also been developed to detect and extract road line data from captured images with a view to both assessing retroreflectivity and mapping these data for maintenance planning.