Question: Reduce Setup Time Hammond Inc. has analyzed the setup time on its computer-controlled lathe. The setup requires changing the type of fixture that holds a
Reduce Setup Time
Hammond Inc. has analyzed the setup time on its computer-controlled lathe. The setup requires changing the type of fixture that holds a part. The average setup time has been 135 minutes, consisting of the following steps:
| Turn off machine and remove fixture from lathe | 10 | minutes |
| Go to tool room with fixture | 15 | |
| Record replacement of fixture to tool room | 18 | |
| Return to lathe | 20 | |
| Clean lathe | 15 | |
| Return to tool room | 20 | |
| Record withdrawal of new fixture from tool room | 12 | |
| Return to lathe | 15 | |
| Install new fixture and turn on machine | 10 | |
| Total setup time | 135 | minutes |
a. Why should management be concerned about improving setup time?
A
longshortlong
setup will result in a
smalllargelarge
production batch, which
decreasesincreasesincreases
work in process inventory and
decreasesincreasesincreases
lead time.
SmallLargeLarge
work in process inventory commits working capital that could be used for other purposes. Long lead times
decreaseincreasedecrease
the companys ability to respond to changes in customer demand.
b. Which of the following are the ways to improve Hammond Inc.'s setup time?
- limit the trips to the tool room to one round trip, rather than two.
- change the location of the fixtures to reduce lathe setup time.
- eliminate the tool room and instead locate the tools in a visible location near the lathe.
- change the entire lathe room layout, so that fewer steps are required to turn the lathe on and off, as well as clean the lathe and change fixtures for the lathe.
- All of these are ways to improve setup time.
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c. How much time would be required for a setup, using your suggestion in (b)? $fill in the blank 8 minutes
Feedback
a. Review the relationship of batch size to setup effort spent preparing an operation or process for a production run.
b. Recall that a setup is the effort spent preparing an operation or process for a production run. If setups are long and costly, the batch size for the related production run is normally large in order to spread this cost.
Learning Objective 1.
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