Developing a standard pre-setup procedure for machines

Abstract: To find success for manufacturing companies in the global market they need to meet and satisfy customer demands rapidly and productively. Therefore, many manufacturing companies are implementing lean techniques and tools to reduce waste and achieve their production targets. The decrease in setup time process using pre-setup configuration helps in increase production rate and machine availability. The key rules of the pre-setup concept are to reduce time in the setup of the machine, decrease unnecessary transportation of setup tools and clear instruction for the machine setup operator. The pre-setup concept can be easily and quickly adopted into current setup process. The improvements from the pre-setup process can be noticed in machine availability and reduce in setup time process in a short period of time to achieve the targeted production rate. This research presents a methodology to assess the pre-setup process in a manufacturing system. This research is divided into two parts, wherein the first part the problems and area in which setup can be improved are identified and in the second solution for the identified problem is presented. The study is carried out using two research methods they are a literature review and case study. The literature review assessment criteria for each characteristic of pre-setup is noted down and solution for the identified problems are developed.