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Setup Reduction Manual Table Of Contents This should help you see just how comprehensive this manual is! Chapter One: Basic Premises 1 The importance of improving CNC machine utilization 1 CNC machine utilization versus application 1 Machine utilization versus personnel utilization 2 Criteria for wise decisions 3 --Company type 3 --Other factors contributing to a company’s identity 5 -- Company philosophies 11 Watch out for conflicts in company type, company profile, and company philosophy! 11 --Which programming method should you use? 11 Definitions for CNC machine usage 12 The importance of value added principles in the CNC environment 16 What’s wrong with this picture? 18 Chapter Two: Setup Reduction Principles 19 The importance of reducing setup time 19 Should you reduce setup time or cycle time - or both? 19 Justification for setup time reduction 21 The relationship between production quantities, process, and setup time 22 What are you trying to improve? 23 Setup time defined 23 -- Do you agree with our definition? 24 The two types of setup tasks 25 The three ways to reduce setup time 25 --Eliminate tasks 25 --Move tasks off line 26 --Facilitate tasks 27 Convenience features versus setup time 27 Available resources 28 --Ingenuity of your people 28 --Purchased items 28 --Thorough understanding of machine & control features and functions 29 --Parametric programming 29 --Our suggested techniques 29 Four steps to setup reduction 29 --A suggestion for getting started 32 --Getting help 33 Chapter Three: Setup Reduction Techniques 35 Preparation and organization for setup 35 A well-designed work area 37 Other factors that contribute to a setup person’ ability to be organized 38 Job order planning 39 Standard tool stations 39 Taking advantage of non-production time 40 Tasks related to preparing to make a specific setup 40 Workholding setup for machining centers 42 Eliminate workholding setup tasks 43 -- Eliminate the need for squaring the workholding device with the table 43 --Do you have any parameters to change? 46 Move workholding setup tasks off line 46 Facilitate workholding setup tasks 47 Workholding setup for turning centers 47 A note about the workholding device 48 Eliminate workholding setup tasks 48 --Do you have any parameters to change? 49 Move workholding setup tasks off line 50 Facilitate workholding setup tasks 50 How hard is it to replace top tooling? 51 --What about quick-change chucks? 52 --Facilitating the task of jaw machining 52 --Why not program the jaw boring process? 56 Cutting tools for machining centers 58 The difference between cutting tool setup and cutting tool maintenance 58 Eliminate cutting tool tasks 59 Move cutting tool tasks off line 60 Facilitate cutting tool tasks 65 How tool life management systems affect setup time 69 Cutting tools for turning centers 70 The difference between cutting tool setup and cutting tool maintenance 70 Eliminate cutting tool tasks 70 Move cutting tool tasks off line 72 Facilitate cutting tool tasks 72 Program zero assignment for machining centers 75 What are program zero assignment values? 75 Eliminate program zero assignment tasks 76 --How do you determine the program zero assignment values the first time a setup is made? 78 --How do you keep track of a job’s program zero assignment values? 79 -- More on sub-plates 80 Move program zero assignment tasks off line 83 Facilitate program zero assignment tasks 83 --What if you don’t have a spindle probe? 83 Program zero assignment for turning centers 86 What are program zero assignment values? 86 --Initially coming up with program zero assignment values 87 Eliminate program zero assignment tasks 88 Move program zero assignment tasks off line 88 Facilitate program zero assignment tasks 88 --Don’t force setup people to reset all program zero assignments in every job 89 --Use tool touch-off probes 90 -- What if you don’t have a tool touch-off probe? 91 Program development 92 Manual programming: 92 Computer aided manufacturing (CAM) system programming: 92 Conversational (shop floor) programming 92 Remember! Programming inconsistencies can affect setup time 93 -- How many programs are we talking about? 93 Eliminate programming tasks 93 --When is a program considered proven? 94 Move programming tasks off line 95 Facilitate programming tasks 95 -- Do you run parts in a family? 96 Program transfer 97 The need for program transfer 98 Eliminate tasks related to program transfer 98 Move program transfer off line 98 Facilitate program transfer 98 --Use a DNC system 99 Program verification 101 Tasks related to program verification 101 Program verification defined 102 --How important is it that your first workpiece be a good one? 102 Eliminate program verification tasks 103 --When is a program considered proven? 103 --How are you handling other setup-related tasks? 104 Move program verification tasks off line 106 Facilitate program verification tasks 107 --Facilitate the task of trial machining 108 -- Here are some examples of trial machining. 109 --Eliminating tool pressure problems when finish turning or boring 111 --Facilitating the sizing for lengthy threading operations 113 --Facilitating finish boring on machining centers 115 --Other potential applications for trial machining 116 -- Facilitate process (machining order) changes 117 What about first workpiece inspection? 119 --Eliminate first workpiece inspection tasks 120 --Move first workpiece inspection tasks off line 120 -- Facilitate first workpiece inspection tasks 120 Program optimizing 121 The one-second rule 121 Eliminate program-optimizing tasks 121 Move program-optimizing tasks off line 122 Facilitate program-optimizing tasks 122 Other tasks related to making setups 124 Appendix A: Setup reduction planning form 125 Index 129

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