Case Studies

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Status quo (outlined):

• Machine cuts, grinds and mills parts from bar stocks.
• Large batch sizes, to reduce the number of setups → company focuses on maximum capacity utilization
• Machines are stopped during the entire setup process.
• The setup process is performed by one employee.

Actions planned by the company:

None. Large batch sizes (causing high WIP (work in process; inventories)) are considered ideal.

Master plan by SYNCRO EXPERTS:

Reduction of setup times by at least 50%.

Approach:

• Recording of every single step of a setup process including the respective time increments
• Visualization of the current state
• Separation of internal setup operations (require the machine to be stopped) and external setup operations (can be performed during machine operation)
• Conduction of the ECRS analysis (Eliminate, Combine, Rearrange, Simplify)
• Involvement of the machine operators as experts
• Development of a masterplan
• Implementation of the optimized setup process according to the masterplan
• Trial run
• Go live

Results:

Initially: A number of setup steps have been rearranged, to be performed as external setup operations (can be performed with the machine still running) → Setup time reduction by 55%

Further Optimization: A second machine operator assists during the setup process → Setup time reduction by a total of 70%

Your Contact:

Thomas Schneider

 

Questions?

+ 49 441-361 85 222

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