Set-Up Time Reduction and Mistake Proofing Methods: an Examination in Precision Component Manufacturing

Set-up time reduction and mistake proofing can be achieved by either traditional approach or by using Single Minute of Exchange of Die (SMED) and Poka-Yoke. There have been many researches on these topics but little advancement has been made since they were developed in 1961 and 1965 respectively, but many case studies have illustrated their successful implementation. These cases have concentrated more on technical implementation with little or no critical evaluation and little on social and cultural factors.
In order to study the critical success factors relating to the implementation of SMED and Poka-Yoke four precision component manufacturing companies we analyzed– two in automobile sector and two in aerospace sector. Mistake proofing devices used by these companies were classified as control method or warning method.

----Control Method----
Control methods are triggered when an abnormality occurs by halting the machine or process thereby preventing occurrence of series of defects. They are more regulatory in nature than warning methods. The major control devices used are –
• Jigs – employed as contact method for eliminating operator error
• Peg Or Guide Pins – cheap and effective way of ensuring the components are inserted the correct way
• Beam Sensors – photoelectric beams used to ensure component is in desired position
• Reset And Interlock Devices – use sensors or limit switches to ensure the machine halts on error
• Gauges – dial gauges were used to indicate the amount by which variations occur

----Warning Method----
Warning methods are also triggered by an abnormality but they do not halt the machine or the process but merely display a warning by using a light or a sound system. The workers can choose to ignore these warning signals due to which the errors will continue to occur. In the companies studied, light system was used to inform the operator that an error has occurred. Sound systems like buzzers were also used. These systems were... [continues]

Read full essay