In a machine shop with 45 employees, a four-axis CNC lathe was used to make large aerospace parts that were shipped on a monthly basis. The change over and setup for one of the routine parts was taking just under 16 hours (two shifts). Since the set up took so long, the company was typically making 3-5 months worth of parts at a time and store them and then ship them out of inventory. Occasionally customers would make changes to parts, which meant that the parts that had already been made were no longer what the customer wanted. Also as the lathe was making parts of a batch of 3-5 months, the lathe was not availabe for other current, more pressing demands.
Six employees spent five days studying the process and reducing the changeover and setup time. A target of 50% reduction was chosen (Shigeo Shingo says, separating external and internal activities will give the size of saving).
At the end of the five day event, one changeover and set up had been done in 7 hours. Additional improvements would take three more weeks to implement setup will take 5 to 5 1/2 hours.
Savings: The company has four of these lathes and by applying what had been learned to all four lathes, sixty four hours per week could now be used for making parts. With changeovers taking less than one shift, the company decided that they would make parts for that month requirement only , so the cost of parts being held in storage was eliminated.
Setup Time Reduction on CNC Shaper 2011 article
MS disseration on CNC Machine Setup Time Reduction 2009 - Haiqing Guo - MIT
CNC Programming Handbook: A Comprehensive Guide to Practical CNC Programming
Industrial Press Inc., 2003 - Computers - 508 pages
Extraordinarily comprehensive, this popular and authoritative reference covers just about every possible subject a typical CNC programmer may encounter on a daily basis. Fully indexed to help the user quickly locate topics of interest, this "industrial strength" handbook presents most common programming subjects in great depth and is equally applicable to both CNC milling and CNC turning operations. Many advanced subjects are also covered, thus making this an unusually comprehensive reference for machinists, programmers, engineers, and supervisors. Filled with over one thousand illustrations, tables, formulas, tips, shortcuts, and practical examples, this widely respected publication is structured in a logical order that is readily adaptable to virtually all levels of CNC training, from the basic to the advanced.
CNC Programming Handbook has just become more valuable than ever! A new CD-ROM, packed with actual problem-solving projects and enhancing the material presented in the book, is included for the first time. Users will find programming projects and exercises for most chapters, special programming and machining projects, solutions to problems, and numerous reference files useful in CNC programming, as well as several utilities. With the majority of files in Adobe PDF, instructors will be able to quickly and easily print and distribute any of the projects, exercises, and references to their classes. Meanwhile, students and professionals will find this CD an effective self-study aid that allows them to enhance their understanding of the subject one topic at a time. Presents complete information on various programming techniques, from the basic areas to dozens of advanced concepts. Includes more than 1,000 illustrations, tables, formulas, tips, shortcuts and real-world examples. Offers unparalleled reference material useful for skills training at all levels of CNC. Presents an encyclopedic, logically organized approach to CNC programming, allowing the reader to look up a subject of interest only. Uses cross references throughout to guide the reader to the proper answer or solution to a problem.
Understanding CNC Machines, Setup and Operation
Richard N. Jackson
Organizational Skills Cut Machine Setup Time
CNC Machining Fundamentals
Zero point mounting kits for setup time reduction
Set up Reduction – A perfect way for productivity improvement of computer numerical control (CNC) set
up in manufacturing company
by - Patel Chintan Kumar, Department of Mechanical Engineering, C. K. Pithawala College of Engineering and Technology, Dumas Road, Surat-395007, Gujarat, India.
17 August, 2012
Benefits of Presetting systems - CNC Setup
How to reduce setup time in CNC tool grinding?
Spencer Tool Setter with CNC software program that assists your operator in accurately measuring and recording tool lengths into the CNC memory.
Setup Reduction For CNC Machining & Turning Centers CD Rom Course $239.00
Vacuum Clamping technology for cnc tools
CNC Tool Cart
Increasing CNC Production throughput with Tool Presetting with a YouTube video of 14 minutes embedded
Workstops and Gang Tool Holders for CNC
CNC Machine Productivity Series Articleshttp://www.cnccookbook.com/CCCNCMachiningManufacturing.htm
CNC Machine Productivity - Basic article
Whether to focus on saving Machine Cycle Time or Machine Setup Time to improve Shop Productivity?
Top Shops - What do they do differently?
Are you using High Speed Machining? - Above 18,000 rpm
By incorporating new CNC programming software to make full use of its new five-axis machining capabilities, Bob Lewis Machine Co. has reduced setups and programming time.
Case Study From: 4/19/2013 Modern Machine Shop
Cycle Time Reduction for Bearing House Assembly
K. Saran Kumar Reddy, T. Panneer Selvam and R. Venkatraman
Published: June 30, 2012
Mill/Turn centers or Multitasking machines.
Drastic Reduction in piece times with high performance cnc machining - 2008
To be updated 7 April 2016