Set‐up time reduction and mistake proofing methods – A study of application in a small company

The paper reports a study into set‐up time reduction and mistake proofing methods in a small company involved in the machining of precision components in small batches with high variety for the aerospace industry. The company has made some set‐up reductions mainly using work study related methods and in one manufacturing cell by the use of the Single Minute Exchange of Die (SMED) methodology. Mistake proofing devices in the form of fouling pins and offset holes have been developed for the family of components manufactured in this cell. Until recently the set‐up times were not measured and worse still were considered as productive hours. As a consequence, there was a lack of awareness and motivation amongst operational personnel to reduce set‐up times and knowledge of SMED was limited to a small group of individuals. This, along with the lack of investment in mechanisms to aid set‐up time reductions and prevent errors, has restricted the use of this type of methods and technology. However, there is evidence that the demands made by the company’s major customer will lead to increased efforts to put into place these types of changes.