Baseline
Data Template
It is very difficult to improve a situation that cannot be measured. Therefore, an adequate amount of time must be dedicated up front in order to gather the appropriate production data and convert them into viable metrics. It is recommended that one year of history be obtained for set-ups, run time, planned, and unplanned maintenance. Be sure to ask the supplier to show you all the available production data. When this information is not available, the Supplier Development engineer should implement means to obtain this information on a day to day basis.
Establish a set-up reduction team:
Cross-functional teams are very effective in reducing set-up times.
Be sure to consider everyone who touches the process as a potential team
member. This could include operators, set-up personnel, maintenance,
scheduling, supervision, and quality control. A typical team will
include approximately five people. Be sure to have representation
from each shift. The use of resource people to assist the team members
is highly encouraged. Employee ownership in the process, a mindset
for continuous improvement, and staying power once the new method is adopted
is critical to achieving optimum results.
Verify the baseline production data:
The set-up reduction team will have the responsibility to review the
baseline production data for accuracy.
Film the set-up:
The set-up reduction team will be required to film an entire set-up. Set-up is defined, as all the steps required from the time that the last piece of the previous job is completed to the time that the next job can be run without any further adjustments or inspections. It may be necessary to film several set-ups to obtain a true picture of the set-up times.
Analyze baseline production data with set-up reduction team:
The set-up reduction team will be required to review the baseline production data and the set-up films. The team needs to document each step in a chronological order. Each step should be classified as either an internal or external element. The people required at each step along with the time required to complete the step must also be recorded. The team will then publish the existing set-up metrics and typical lot sizes for the process.
Document baseline data using the following templates:
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