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The TPM improvement plan 109

Table 5.6 Factors in reduction of set-up and adjustment time

External set-up Tools (types, quantities)
Preparations Locations * Don’t search
0 Position 0 Don’t move
Workplace organization and housekeeping Don’t use
* Preparation procedure
Preparation of a Check jigs
ardlary Measuring instruments
equipment Preheating dies
0 Presetting
Internal set-up Standardize work procedures Eliminate
0 Allocate work redundant
0 Evaluate effectiveness of work procedures
0 Parallel operations Reduce basic
0 Simplify work operation
0 Number of personnel
Simplify assembly
0 Assembly /integration
* Elimination
Dies and jigs Clamping methods Makeit easy
0 Reduce number of clamping parts
0 Shapes of dies and jigs: consider mechanisms
Use intermediary jigs
0 Standardize dies and jigs
0 Use common dies and jigs
0 Weight
0 Separate functions and methods
0 Interchangeability
Adjustment Precision of jigs
Precision of equipment Eliminate
Set reference surfaces adjustment
0 Measurement methods
Simplification methods
Standardize adjustment procedures
Quantification
* Selection
Use gauges
Separate out interdependent adjustments
- Optimize conditions

Table 5.7 Adjustments as a percentage of total set-up time
Preparation of materials, jigs, tools and fittings 20%
Removal and attachment of jigs, tools and dies 20%
Centring, dimensioning 10%
Trial processing, adjustment 50%