Question

What quality implications could setup time reduction have in a manufacturing line? Why is it important to detect quality problems as early in the line as possible?

Answer 1

Non standard time reductions in cycle time or setup time in manufacturing line, has direct impact on PQCDSM - Production, Quality, Cost, Delivery, Safety, Morale.

In quality following points can be considered of concern (for set up time reduction) -

1. Standard Operating Procedure may not be documented and can cause change in method for operator to operator.

2. Activity chart for setup should be available, wherein setup parameters check time should not be compromised.

3. Heist for time reduction, often de-concentrates long term machine maintenance requirement within setup change. This may lead to deterioration of machine/ equipment and part failure in long go.

4. First Product Quality Check is important for defect control. Often in several SMED projects, quality check time is shifted to offline activity, meaning, a number of products are generated by the time first Product is checked and quality approved. This increases potential for defect products.

5. PFMEA revision- Any activity that is reduced to achieve reduction in set up time may give rise to a new failure mode or alternatively increase RPN of identified failure mode.

Identifying problems early in the manufacturing or assembly line, prevent product to slip in extra expenditure. For example, if from software it is identified that product has defect with its design, then rework on design would be cheaper than producing that part and then rejecting a lot.“Good quality practices facilitate increased throughput, reduced WIP, cycle times and customer lead times.”*