Setup Reduction For CNC
Principles
Copyright 2001
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Setup reduction principles:
 Definition of setup time
 Two task types related to setup
 Three ways to reduce setup time
 Four steps to setup reduction
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Definition of setup time:
The time it takes to go from making
the last workpiece in the most
recent production run…
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Definition of setup time:
The time it takes to go from making
the last workpiece in the most
recent production run…
Everything that happens while the
machine is down between production
runs is part of setup time!
…to making the first good workpiece (efficiently)
in the next production run
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Definition of setup time:
By our definition:
If you’re running but one workpiece…
…there is no production run
If you have machines dedicated to one job…
…there is no setup
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Much is directly related to setup:
Tear down old setup & put everything away
Clean machine
Make new setup
Cutting tool tasks
Assemble, measure, and enter offsets for
Assign program zero
Measure position and enter fixture offsets
Load program
Verify program
Optimize program
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But maybe some non-productive activities:
Time spent gathering needed items
Hand tools
Cutting tools
Fixtures
Gauges
Material
Paperwork
Storage containers
?
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Or maybe some non-productive activities:
Time spent gathering needed items
Personal time
Breaks
Lunch
Phone calls
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Or maybe some non-productive activities:
Time spent gathering needed items
Personal time
Time spent waiting
For inspection
For tool crib attendant
For fork lift operator
These are all fair game for your
setup reduction program!
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Compare core tasks to non-productive tasks!
Core tasks:
Tear down old setup & put everything away
Clean machine
Make new setup
Cutting tool tasks
Assemble, measure, and enter offsets for
Assign program zero
Measure position and enter fixture offsets
Load program
Verify program
Optimize program
Non-productive tasks:
Time spent gathering needed items
Personal time
Time spent waiting
For inspection
For tool crib attendant
For fork lift operator
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One more point…
Setup time: the entire time a machine is
down between production runs
Cycle time: the time it takes to complete a
production run divided by the number of
good workpieces produced
Think about it…
…machines are either in setup or running
production – there is nothing else!
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Two setup-related task types:
On-line tasks:
Tasks done while the machine is
down between production runs
Off-line tasks:
Tasks done while the machine is in
production for the next (or some future) setup
Setup time is the sumtotal of all on-line tasks!
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Two setup-related task types:
Tasks commonly done while the machine is down
Tear down old setup & put everything away
Clean machine
Make new setup
Cutting tool tasks
Assemble, measure, and enter offsets for
Assign program zero
Measure position and enter fixture offsets
Load program
Verify program
Optimize program
The fewer the people in the
CNC environment, the more
tasks tend to be done on line
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Two setup-related task types:
Tasks commonly done off line
Programming
Cutting tool assembly
Gathering of hand tools
Gathering of fixtures
Gathering of gauges
The more people in the CNC
environment, the more that
can be done off line
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Two setup-related task types:
Important points:
The machine is down during the
performing of on-line tasks
The machine is running during the
performing of off-line tasks
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Two setup-related task types:
More about off line tasks
Off-line tasks are affected by lot size and
cycle time…
…with small lots and short cycles, there
won’t be time to do anything off line!
Even with large lots…
…if cycle time is short, the operator won’t
have time to do anything during the CNC cycle!
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Three ways to reduce setup time:
Eliminate (especially on-line) tasks
You save the amount of time it was
taking to perform the task
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Three ways to reduce setup time:
Eliminate (especially on-line) tasks
Eliminate
the
task
You save the amount of time it was
Remember,
given unlimited
taking to perform
the taskresources, there
is no task that cannot be eliminated!
Don’t be too quick to give
up on eliminating tasks
Ingenuity plays a big part!
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Three ways to reduce setup time:
Eliminate (especially on-line) tasks
You save the amount of time it was
taking to perform the task
Move on-line tasks off line
At least the machine is not down during the
performance of the task
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Three ways to reduce setup time:
Eliminate (especially on-line) tasks
Move
the
task
off
line
You save the amount of time it was
Many
canthe
be done
taking
to tasks
perform
task while the
machine is running production
Move on-line tasks off line
Assumes you have adequate lot sizes,
At least
the
machine
is
not
down
during
the
cycle times, and available personnel
performance of the task
Often requires duplications (especially tooling)
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Three ways to reduce setup time:
Eliminate (especially on-line) tasks
You save the amount of time it was
taking to perform the task
Move on-line tasks off line
At least the machine is not down during the
performance of the task
Facilitate tasks
Make it as quick & easy as possible to
perform the task
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Three ways to reduce setup time:
Eliminate (especially on-line) tasks
Facilitate
the
task
You save the amount of time it was
The
a task
to perform,
taking
to easier
perform
the is
task
the faster it can be done!
Move on-line tasks off line
Task simplification makes it possible for
At people
least the
machine
is
not
down
during
the
with lower skill to perform well
performance of the task
Often
the easiest alternative to justify
Facilitate
tasks
Make it as quick & easy as possible to
perform the task
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Three ways to reduce setup time:
Eliminate (especially on-line) tasks
You save the amount of time it was
taking to perform the task
Move on-line tasks off line
At least the machine is not down during the
performance of the task
Facilitate tasks
Make it as quick & easy as possible to
perform the task
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Remember – feasibility doesn’t always
equal possibility
Your first goal:
Eliminate the task!
If that’s not feasible:
Move the task off line!
If that’s not feasible:
Facilitate the task!
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Regardless of whether you are trying to
improve an entire setup…
…or but one task that is performed in many
setups…
…there are four basic steps
1)
2)
3)
4)
Evaluate current methods
Brainstorm for improvements
Assign and implement changes
Gauge success
Planning form is in your manual
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Step one: Evaluate current methods
We’ll show many ways to change
the way you make setups
With the goal being to reduce setup time
But some changes may have
unexpected consequences
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Step one: Evaluate current methods
You must be able to gauge the impact of
any change on your CNC environment!
Since we’re talking about setup time
reduction…
…most evaluations will be gauging time
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Step one: Evaluate current methods
The time required to performing a task
is directly related to its complexity
Since facilitating (simplifying) tasks is
one way to reduce setup time…
…you must also be able to evaluate the
complexity of tasks to be improved
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Step one: Evaluate current methods
You must be able to gauge the impact of
any change on your CNC environment!
The best way is to video tape
the task…
Get everyone’s approval
Watch for unusual behavior
Use a camera with time/date
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Step one: Evaluate current methods
You must be able to gauge the impact of
any change on your CNC environment!
…another way is to simply
time the task
But it will be much more
difficult to evaluate complexity
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Step one: Evaluate current methods
You must be able to gauge the impact of
any change on your CNC environment!
Tool Assbly
Work Holding Setup
Tool Meas
Teardown
Tool Loading
1st Piece Insp.
Prog. Zero Meas.
Offset Entry
Program Loading
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Program Verification
What you may find:
A high degree of disorganization!
Organization of hand tools
Organization of cutting tools
Organization of fixtures
Cleanliness of work area
Misplaced items
Poor documentation
Minimal engineering support
Conflicting methods
No communication
Tooling not available
Your greatest initial improvement may be…
…to get better organized
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Setup reduction form:
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