People are constantly amazed at how much time is wasted through disorganization and general messiness. Improving elements and eliminating adjustments will require more imagination, time and cost. Even here, the improvements are sometimes astonishingly simple and easy. The solution that can reduce set up time is organize and housekeeping the factory. It often that setup problems are related to poor maintenance such as worn parts, worn tooling, dirt, or damaged threads.Disorganization and poor housekeeping are also contributors to setup problems. These are easy to fix and should be a first step.
Next solution is examining each internal element and sees if it cannot be done externally. For example, the pre-heating of an injection molding die could be done before it goes into the machine. After that examine every element to see how we can eliminate it, simplify it, reduce the time required or improve it in some other way [9].
In many cases, defective material handling procedures can scrap or damage materials. Defective material handling systems can be improved by performing process failure mode and effects analysis to identify operating procedures required to reduce or eliminate the defects. When designing new material handling systems, perform a design failure mode and effects analysis on the equipment to identify and eliminate sources of damage [8].
As bad as they might be, the previous are insignificant in comparison to a customer discovering your defects for you. Not only are extra warranty and delivery costs involved, but customer dissatisfaction might result in loss of future business and market share.
Eliminate defect waste at the source by establishing a system to identify defects as they occur. Authorize anyone on the plant floor to take corrective action. Without this preventive system in place, other time-saving efforts are futile. There's no advantage to using highly automated machinery to make defective parts faster.