11

Excessive speed above standard

Reduce speed to standard

Some of the remedies will require a skilled maintenance fitter. Others can be carried out by the operator with some training (items 4, 5, 8, 9 and 11). Vibration is identified by sight, touch or noise increase.

Some of the remedies will require a skilled maintenance fitter. Others can be carried out by the operator with some training (items 4, 5, 8, 9 and 11). Vibration is identified by sight, touch or noise increase.

of the importance of tackling adjustment is given by the percentage figures based on hard experience shown in Table 5.7.

Set-up and adjustment are so important in the drive towards reduced losses, better equipment effectiveness and ultimately world-class manufacture. Shigeo Shingo, the guru of Single-Minute Exchange Die (SMED), states the following in his book A Revolution in Manufacturing: the SMED System: 'Every machine set-up can be reduced by 75%'.

What a challenge for Western companies! The SMED approach uses a derivative of the Deming circle:

Focus Set-up video

Analyse Pareto, ergonomics

Develop Script, simulate, agree

Execute Train, measure, honour, empower

In the SMED system, success is subject to certain conditions:

• An attitude The team wants to score.

• An empowerment The team has a budget.

• An involvement Management is part of the team.

• A commitment Management sets the target.

• A philosophy Step-by-step improvement.

Moreover, the SMED approach suggests that there are characteristics common to all set-ups:

• Prepare, position, adjust, store away

• Internal and external activities

• From last good product to first good product

Table 5.6 Factors in reduction of set-up and adjustment time

External set-up

Tools (types, quantities)

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