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Program Benefits:
Variation Buster uses the power of settings to
eliminate the traditional adjustments of process control. These techniques are
based on the Single Minute Exchange of Dies concepts developed by Shigeo Shingo.
These techniques eliminate most of the errors that occur during the adjustment
process, and typically cut variation in half while eliminating the data
collection, process control charts, and the need for statistical process control
on the factory floor. This is the equivalent of going from a 3 Sigma to 6 Sigma
process control without requiring new equipment or tools and reducing the
complexity of the work at the same time. Using settings to setup tools and
fixtures eliminates up to 98% of the mistakes that are committed during setup
operations. Thus, control of variation with settings is also a form of
mistake-proofing because it eliminates mistake opportunities. Setting techniques
enable rapid die changes that are essential for efficient production of a
variety of products on a single production line. Associates implementing these
techniques will realize the following benefits:
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Dramatic reduction in setup errors
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Fewer
processing errors
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Reduction in process variations
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Improved production efficiency
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Faster product changeover times
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Ability to prototype new products
on existing production lines without
disrupting production
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The
ability to rapidly switch
product mix, improving responsiveness
to the market.
Program Description:
The ability to convert adjustments to settings
begins during the session as associates first learn to recognize adjustments,
and the setting techniques that eliminate adjustments. Through the use of
numerous examples, associates learn how to convert adjustments to settings.
Graphic examples clarify reinforce the powerful benefit of settings,
dramatically illustrating the elimination of mistake opportunities while
simplifying and shortening the setup time for fixtures, and tool changes, and
product changes. Armed with the techniques of Single-Minute exchange of Dies (SMED)
participants will learn how to convert on-machine setup actions to off-machine
preparation. They will learn how to eliminate wasted actions, such as tightening
a threaded fastener through many revolutions to fasten a fixture to production
equipment. Associates will learn to recognize how statistical data collection
can be eliminated while improving the control of variation. Associates will
apply these techniques to production processes in their work environment,
developing ideas that have immediate application in their work environment.
Implementation and Customization:
These techniques can be applied immediately to associate's products and
processes. Our flexible approach can be quickly and expertly tailored to reflect
your company’s specific products and concerns.
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Product Details:
Variation Buster is a
production tool that
can be facilitated by product design. Design and
production teams working together or independently in
small teams
benefit
most, although
teams can be
trained in large
groups.
Although this tool is
appropriate for low
to high volume
production, it is
a useful tool
whenever variety,
production mix,
or small batch
sizes are desired |
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