Unit 5 - Setup Time Reduction

Question 1

Define setup

Answer 1

The elapsed time between making the last food part of item A and the first good part of item B

Question 2

What is the traditional approach to setups

Answer 2

Setup is given and fixed so companies use highly skilled setup personnel, minimize their product variety, combine lots, and produce in large batches

Question 3

What are internal setups

Answer 3

A step that must be performed wile the marching or operation is stopped

Question 4

What are external setups

Answer 4

A setup that can be performed when the machine is running

Question 5

What are the components of SMED methodology

Answer 5

Identify internal and external steps
Convert internal steps to external steps
Improve all aspects of the setup operation
Abolish setups

Question 6

What are type 1 setups

Answer 6

External
Retrieving, preparing, and checking materials and tools before and after the setup

Question 7

What are type 2 setups

Answer 7

Internal
Mounting tools and parts prior to the next batch then removing them after completion of the last batch

Question 8

What are type 3 setups

Answer 8

Internal
Measuring, setting and calibrating machine tools and fixtures

Question 9

What are type 4 setups

Answer 9

Internal
Producing a first off part after initial machine settings and measuring the piece then adjusting the machine settings until the test piece meets production requirements

Question 10

What methods can be used to separate internal steps from external

Answer 10

Checklists
Equipment checks and repairs
Setup schedules

Question 11

How can internal steps be improved

Answer 11

Parallel setup tasks
Quick attachment devices
Eliminate adjustments

Question 12

How can external setup steps be improved

Answer 12

Store fixtures near machines
Prepare setup kits and costs
Improve material handling

Question 13

How can setups be abolished

Answer 13

Reduce or eliminate differences in parts
Combine parts or steps
Dedicate machines to one part