Issue link: https://iconnect007.uberflip.com/i/1411055
16 PCB007 MAGAZINE I SEPTEMBER 2021 Project Results Within six months, the following results were achieved by this project: 1. Lead times were dropped from 15 to three weeks. 2. Order cycle time was reduced from eight to less than three weeks. 3. Work-in-process inventory was reduced over $500,000. 4. Raw material inventory decreased by $250,000. 5. On-time deliveries increased from 35% to over 98%. 6. Labor productivity, in terms of output per hour, almost doubled. Lot Size: Minimizing the Set-Up Time e two value-added times are set-up time and run time. Minimizing set-up time is key to reducing lot size, which allows for low- er costs and more scheduling flexibility. But there are other benefits (Figure 2) to set-up time reduction: • Increased flexibility • Less inventory • Better quality • Reduced startup wastes and rejects • Higher production throughput • Higher machine utilization • Simpler or no setup, thus requiring less operator skills • Safer changeovers Set-up Time Reduction Process Steps: 1. Separate internal and external tasks: Internal can only be performed once equipment is stopped, while external can be performed whist equipment is still running. 2. Convert internal to external tasks: Prepare required tools and instructions at the work center and analyze set-up actions into internal, external, and waste. 3. Streamline all aspects of the setup: Move any tools or instructions needed to the work center and use more than one person to eliminate unnecessary movements. 4. Eliminate adjustments: Establish reference points for all process settings to eliminate trial and error by establishing standard op- erating procedures (SOPs) or by networked automation. Figure 2: Benefits for setup time reductions.