Set up time is the total amount of time it takes to prepare to make the next saleable part, beginning at the time you log off the last job. Set up time includes such activities as the following: · Go to find out what to run next · Find the correct router · Log on to set up per the job number · Clean up from the last job if necessary · Rearrange floor-standing tools from last job · Look for the proper raw materials · Ask others questions about the job or the work center · Take the router to the saw department to get materials cut · Read the Router · Find and talk with management or others for clarification on the job · Look for tooling & tool holders in the tool box · Walk to other tool cabinets to search for tools, as required · Search for those tools in the other cabinet · Negotiate with the person at the other cabinet to borrow tools · Return to your work area · Find the hand tools required to do the set up…walking, searching · Break down and set up the required tooling · Download the program · Determine where the tooling goes in the magazine · Gather floor drill and sander, saw, etc. as required · Go to get a sample piece of raw material, if necessary · Test load the part into the machine · Modify fixtures/jaws as required · Go get raw material if not delivered · Run 1st test piece · Go to QC to get inspection gages and tools as required · Inspect 1st test piece · Take to QC if required, or · Find another person to double check dimensions · Make adjustments to machine as needed to produce a good part · Repeat until achieving good part at router-rated pieces per hour · Make any final finishing adjustments, including cleaning off work cabinet and laying out measuring instruments in logical order · Find QC sheet and fill in dimensions, if necessary · Find and set up packing materials · Find tape gun and tape if required · Find and arrange carts for raw and finished materials · You have now completed the set up functions. You are ready to run production. Log off SET UP and log on to RUN. Nothing you have done up to this point in the job is billable to the customer! (And I probably left out some steps you sometimes have to do to get the job running properly.) We cannot get paid for any of this time. The company (you) have worked for free up to this point on the job . The above scenario illustrates why everyone needs to be concerned how long it takes to set up jobs. A major part of lean manufacturing focuses on minimizing set up time; often called set up reduction. Set up reduction is important in all businesses, but is absolutely critical to success in a job shop. Next week we will begin discussing how to reduce set up time.