The setup and adjustment improvement manual

１. The necessity of the time reduction by the setup and adjustment

　There are extremely many lines by which the product changes a kind in the manufacturing line.The loss of the setup and adjustment lot stock and the down time is making productivity decline for its purpose.
In addition to the improvement of merely the facility overall efficiency of the improvement result of the time reduction by the setup and adjustment It reduces lot stock by doing a setup and adjustment, being small and the production lead time can be reduced. That is, the whole production system becomes flexible.
Also, the improvement contents of the setup and adjustment are reflected in the design of the facilities to plan to do next as the MP information.

２． The classification of the setup and adjustment exchange

　It is classified as follows by the manufacturing process.
① The exchange type of the mold　
･ The stamping, the resin formation, the casting, the die cast and the hammering-out and so on
② The exchange type which is cutting tools and Jig
･ The machine manufacture, the weld and the assembly and so on
③ The control program change type
･ The robot painting ･ The automatic assembly ･ The electron element mounting machineand so on
The exchange of the conveyance nail and the product supply forwarding part of the product and so on accompany in the case of either.

3. The viewpoint of the setup and adjustment abridgment improvement

　When roughly dividing setup and adjustment work, it is divided into "setup and adjustment's working outside" and "the inside setup and adjustment work".Moreover, "the inside setup and adjustment" is classified into "the preparation work", "the exchange work" and "the preparation quality confirmation work".
The viewpoint of each work improvement is as follows.

The improvement viewpoint of "the preparation work"
① Making a setup and adjustment out of the preparation
② It specializes a tool and then it fits up the tool on the work position.

The improvement viewpoint of "the exchange work"
③ The one touch, the quickstep changing, it makes fastening-up a less of the bolt.
④ The abridgment of the movement walking distance and the approaching by it
⑤ The same time work

The improvement viewpoint of "the preparation quality confirmation work"
⑥ It loses an adjustment (Bumping in the block from the graduation adjusting).
⑦ It fixes a positioning basis
⑧ Doing one becoming of the article of good quality
　The factor analysis implementation with the worse of one（It analyzes why why.The PM analysis

The viewpoint of the common improvement
⑨ The safe-ization of the work
⑩ The leveling of the work procedure

4. The way of implementing setup and adjustment improvement

　The procedure of the concrete setup and adjustment improvement grapples with the following improvement step. Then, it always makes "the exhibition setup and adjustment" basic.
This "the exhibition setup and adjustment" does a setup and adjustment by the operator who was most mastered in a lot of observers Therefore, it lets out an improvement item from the viewpoint of above-mentioned improvement, and it shares and it implements improvement It repeats this "the exhibition setup and adjustment" many time and it piles further improvement.
Next, it trains to standardize a work procedure after this improvement and to be made of the time of the setup and adjustment that the other operator, too, is the same and it makes "the time of the exhibition setup and adjustment"="generally, are the time of the setup and adjustment".

The way of implementing "the exhibition setup and adjustment"
　The exhibition setup and adjustment is the purpose to do the present situation grasping of the setup and adjustment work and the finding of the improvement item, the confirmation of the improvement effect. Then, it is the setup and adjustment to implement in the attendance of the relation section, the staff, the manager.(It is equal to or more than 10 even if it is minimum in all).
It is the place which depends and exposes an improvement item and an improvement idea with the activation of the improvement activity of the setup and adjustment and the eyes of a lot of persons.

The implementation point
1. It notifies the date and time of the implementation of the exhibition setup and adjustment to the participant beforehand.(Participant : The factory manager, the relation office organization, the manufacturing technique staff, the supervisor, the promotion secretariat and so on)
2. The preparation of the necessary record, the implement
　（･ The time study table・The time graph of the setup and adjustment ･ The item finding table ･ The video camera ･ The chronograph ･ The pedometer ･ The bib ･ The whistle ・The host it）
3. The indication of the role share to the participant
　（The record taking charge of the time, The video photography taking charge, The work content explanation taking charge, The others do improvement item extraction and extraction with non-safety work.）
4. The worker of the setup and adjustment puts a bib and a pedometer and works.
5. After the setup and adjustment ends, it argues the work of the improvement item while seeing a meeting video at the boardroom
.It sticks in a host it in the item finding table. It enters the more detailed tally in the work diagram table.
6. It decides the exhibition setup and adjustment plan day taking charge of the improvement, the implementation plan of it and next time.

5. The active step of the setup and adjustment improvement

The step	The activity The name	The activity The contents
１step	The active plan and the goal setting	･ It makes a setup and adjustment improvement plan.The active member, the active schedule, the par setting ･ 1/2 of the par with the present situation value is the 1st step.It makes of the final result later and moreover 1/2.
２step	The present situation grasping (Exhibition setup and adjustment -1)	･ It implements "the exhibition setup and adjustment" of the present situation grasping. ･ It makes "the setup and adjustment work diagram" (not click -- still inputting here) from the work tally. ･ It sets up to the improvement item bill and it puts the improvement item (the host it) to have let out from the participant. (Preparation, the exchange and the preparation quality confirmation) ) to stick in particularly (the small improvement, improving in, big improving) the frame
３step	The improvement item finding	･ It examines a concrete improvement idea and an implementation item from the improvement item table and it puts them in order. (It prepares the book of the improvement idea and so on beforehand). ･ It puts taking charge of the improvement implementation and a schedule in "the improvement implementation progress table" in order.
４ step	The improvement implementation result confirmation (Exhibition setup and adjustment -2)	･ The implementation of the improvement ･ The item which needs big improvement computes an expense vs. an effect and fixes implementation right or wrong. ･ If the small improvement, in the improvement level can be implemented, it implements "the exhibition setup and adjustment" of this improvement effect to confirm. ･ It implements 2-3 steps repeatedly.
５step	The factor analysis and the measure of doing one becoming of the article of good quality	･ It implements a factor analysis about one quality defects after setup and adjustment. (Analysis tool : It does "analyzing why why" or "the PM analysis"). ･ It does the investigation of the factor analysis and it implements restoration improvement in the defect of the investigation result.
６ step	The standardization of the setup and adjustment work procedure	･ It puts a work procedure after improvement in the standard operation book in order.
７step	The implementation of the work training and the issue of the MP information	･ Based on the standard operation book, it implements setup and adjustment work training to the other operator. Then, it trains until are made of the time which is equal to the time of the exhibition setup and adjustment . ･ It puts improvement contents in "of the improvement before-after improvement" sheet in order (The photograph and the explanation). It publishes this to the manufacturing technique subdivision as the MP information.

６． The case of the setup and adjustment improvement

① The resin formation mold setup and adjustment case (In case of crane hanging mold exchange)
･ It installs a place in the resin formation machine-type set center position in the place of the mold (It loses the one-way movement of the crane).
･ It makes the placing stand of the mold high (It makes a movement at the top and the bottom of the crane little).
･ It sets a few spare temperature adjustments by the mold to the improvement temperature (It expects the temperature decline to be exchanging).
･ It installs an arrow fitting mark in the movement stop position of the crane (It loses the movement fine tuning of the crane).
･ It fits up the positioning block of the mold and the formation machine on the tail (The scaling of the mold base).
･ It makes the plumbing connection coupler of the cooling water temperature adjustment equipment of the type to do multi- becoming of the coupler and it is concentrated (in the) front (constant direction).
･ It makes the fastening-up clamp of the type a hydraulic pressure clamp.
･ It makes Dog of the recession position limit SW of the type tightening-up turn Dog bar.
･ It makes an independent operation console panel the operation exclusive use of the setup and adjustment, it is independent and it installs it in the work position (It loses the walking which is because of the operation).
･ It makes the input of the resin formation condition one touch input.
･ It makes a hopper 2 reams and it loses the hopper cleaning time of the color exchange.
･ It makes an article of good quality by the 2-cycle shot even if it is minimum (It exhausts an ejaculation color change by the first shot).
･ It is taking and it exchanges a one touch of the gripper of the equipment

② The case of the mold setup and adjustment of the transfer stamping
･ It makes connection wiring plumbing to the type multi- coupler and then it puts the adjustment mark of the coupler.
･ It cleans a scrap by the pre-setup and adjustment preparation by the movement rail surface of the mold cart.
･ It makes the movement movement speed of the mold cart early.
･ It makes the connection guide kind of the conveyance bar of the mold to do the one touch becoming of the desorption.
･ Of two operators it works in the leveling.

③ The improvement case of the setup and adjustment of the cut machine, the welder and the general facilities
･ It makes the positioning of jig a bump standard.
･ It clamps an L of the fastening-up bolt of jig (It makes a bolt loosening tightening-up within 180 degrees)..
･ Doing the part exchange bolt of the jig the length hole C becoming of the washer
･ Doing a conveyance grip the one touch becoming of the desorption
･ It makes on replacement by the inspection tools the anti-movement replacement method of Merry go Land formula.
･ It makes LS Dog's movement to move by the bump bar or it makes turn Dog a bar.
･ It makes cop box on replacement by the attachment part (the product) a Merry go Land formula anti-movement replacement method.

(Later, it plans above-mentioned improvement case photograph in the carrying).

Returns to the TPM top page.

Returns to the automatic line improvement page .