Set-Up-Time Reduction: Shorter Lead Time, Lower Inventories, On-Time Delivery, The Ability to Change Quickly [Hardcover]

Jerry Claunch (Author)

Book Description

ISBN-10: 078630863X | ISBN-13: 978-0786308637 | Publication Date: April 1, 1996 | Edition: 1

Every company is feeling the pressure to be more responsive to the needs of their customers, to repsond to the increased competition in the global marketplace, and to adjust to ever-shortening product life cycles. Today, the most agile manufacturing organizations are using a reductiion in their set-up times to capture the competitive advantage that increased agility offers. Although many companies have made impressive strides axross the board by implementing a Just-In-Time philosophy and by cutting down their response times, the positive effect reducing set-up time has on every subsequent operation is remarkable. Set-Up Time Reduction is a timely, authoritative, and practical book on how to make the initial steps of the manufacturing process faster, more efficient, and easier on the bottom line. Set-up time reduction program managers and individual team members will find ideas for: Adopting a team approach to reduce set-up times--including concepts for brainstorming solutions. Monitoring safety during implementation. Avoiding the pitfalls of a set-up time reduction program.

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Product Details

• Hardcover: 200 pages
• Publisher: McGraw-Hill; 1 edition (April 1, 1996)
• Language: English
• ISBN-10: 078630863X
• ISBN-13: 978-0786308637
• Product Dimensions: 9.3 x 6.2 x 0.9 inches
• Shipping Weight: 1 pounds (View shipping rates and policies)
• Average Customer Review: 4.0 out of 5 stars  See all reviews (2 customer reviews)
• Amazon Best Sellers Rank: #2,416,664 in Books (See Top 100 in Books)

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Customer Reviews

Most Helpful Customer Reviews

15 of 15 people found the following review helpful:

5.0 out of 5 stars Definitely the best book I have seen in this area., March 16, 1998

By 

[e-mail] (USA) - See all my reviews

This review is from: Set-Up-Time Reduction: Shorter Lead Time, Lower Inventories, On-Time Delivery, The Ability to Change Quickly (Hardcover)

I teach and consult in the area of setup reduction. I recently chaired a conference at which Jerry Claunch spoke and saw his book for the first time. I bought it on the spot and read most of it on the plane home. It is excellently written and gives a great deal of detail about WHY setup reduction is so critical and, more importantly, HOW to achieve it. Although I pride myself on expertise in this field, I learned many things from this book. It is a MUST READ for anyone in manufacturing.

3.0 out of 5 stars Nice book - but not for beginners, April 10, 2007

By 

O. David (Schweiz) - See all my reviews
(REAL NAME)   

This review is from: Set-Up-Time Reduction: Shorter Lead Time, Lower Inventories, On-Time Delivery, The Ability to Change Quickly (Hardcover)

Whether you start your Lean/ JIT journey or you want to implement Quick-Response-Manufacturing, one of the cornerstones will be how to reduce lot-sizes in production. Reducing lot-sizes have a high impact on faster LT/ cycle time because of the almost one-to-one reduction in queueing time, wait-to-batch-time and wait-in-batch-time etc. If you reduce lot sizes and variability in arrivals and variability in processing (use TPM as well) you will also reduce the work-in-process (WIP) - as Little's law simply shows. There are many practical studies showing as well, that smaller lot sizes have a high impact on quality improvements.

What is set-up time reduction? Often large lots are ran, because of not knowing the bad influence of large lots on cycle time/ LT and the understanding, that smaller lots will flaw capacity of a work station. In order of not to loose "capacity" with too many change overs and to profit from small lot sizes, you need to reduce the change over time itself. In the western countries change over times is seen as a given, instead there are tools, that allow simple reduction of set-up times by 50% or even more in a quit simple manner. Reductions in set-up time have almost an impact from one-to-one for the reduction of the lot size: cutting a set-time by half almost allows to half your lot size by half. The tool and method to reduce the set-up time and to achieve small lots is known as SMED: Single-Minute-Exchange of Die. The basic insight is to separate the internal set-up from the external set-up. This means to separate the different steps required for a set-up into things that can be done meanwhile a machine is still running or things that can really only be done, when the machine is stopped. Furthermore there are approaches for internal and external set-up steps to eliminate handling and to further reduce the set-up time. Very important from a practical point of view are the use of special fasteners etc. that are key for a fast change over.

This book is written in an easy and understandable manner. Anyway, as a beginner, there are better books to be read at the beginning. What I missed most about this book here, is a clear approach and description of the method itself. The book "Quick Changeover for Operators: The SMED System" from The Productivity Press Development Team does a much better job in explaining step by step the method. The book mentioned here includes nice pictures of fasteners etc., but the simplier book "Quick Changeover for Operators" uses much more usefull figures and drawings to understand the text itself.

Conclusion: As a beginner in this matter read the book "Quick Changeover for Operators". Even though I did not buy many further books on this topic, I'm quit sure, there are better and more state of the art books available about SMED than tis one ("Set-up Time Reduction"). Look as well about Shigeo Shingo, the man that invented SMED (former Toyota chief Engineer). More information on this topic you will find here:

[...].
Best Regards,
Oliver