Table 5.7 Adjustments as a percentage of total set-up time

Preparation of materials, jigs, tools and fittings 20%

Removal and attachment of jigs, tools and dies 20%

Centring, dimensioning 10%

Trial processing, adjustment 50%

Figure 5.32 Analysis of adjustment operations

4 Principles What is the true function of the adjustment operation as a whole?

5 Causal factors What conditions create the need for adjustment?

6 Alternatives What improvements will eliminate the need for adjustment?

Figure 5.32 provides a clear visual presentation of the TPM approach to analysing adjustment operations leading to minimization of losses. Figure 5.33 reviews progressively the process from an analysis of the present position right through to achieving optimal conditions. Wherever possible, make use of video: it is a very powerful analysis tool.

Set improvement targets (the challenge)

Progress in reducing set-up times

Variable factors


Points requiring attention

Equipment mechanism/system


Scope of set-up operation

Shape mechanism, and precision jigs/tools

Effect on ancillary equipment

Methods and sequence Time

Adjustment methods and details Effectiveness of each operation Pareto analysis (ABC)

Targets based on equipment restrictions Targets based on desired improvement

Preparatory steps (everything to hand)

Separate internal & external set-up operations

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