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:

• Dramatic reduction in setup errors

• Fewer processing errors

• Reduction in process variations

• Improved production efficiency

• Faster product changeover times

• Ability to prototype new products
  on existing production lines without
  disrupting production

• 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.