The set-up process according to the Lean Management principle

May 2020


In April 2019, the Oskar Rüegg decided to optimize the set-up process of its production according to the Lean management principles. To do that, an analysis of the current situation had to be done at first, which was carried out as a multi-day workshop. During this workshop, two setters from Oskar Rüegg were observed during the respective set-up process and each step was precisely documented.

 

After the workshop and the subsequent evaluation, three main changes in the process were carried out:

 

  • The various sub-steps were divided into two categories, internal and external set-up. The external set-up includes those steps that do not yet directly affect the punching machines, such as mounting the coil on the decoiler or picking the tool from warehouse. The internal set-up, on the other hand, refers to all operations that are performed directly on the machine, e.g. removing the previous tool and setting-up the new one. The advantage of this is that the stamping machine only needs to be stopped for the internal set-up activities. During the external set-up, the machine continues to finish previous stamping orders.

 

  • The internal set-up process is now always carried out by two employees. In the past, a single employee was always assigned to each machine and per set-up process. Although more employees are now basically required, the efficiency is increased in that the set-up process on the first machine can be completed more quickly and thus another machine can be set-up and started more quickly.

 

  • Since two setters are now used per machine, the stamping process can be started immediately after the new tool has been set-up. This means that while the first person carries out the measuring process, the second person connects the peripherals that are still needed.

 

Of course, other minor optimizations were also carried out, such as the use of the 5S method for the hand tools or improved planning and coordination of the setters by the team leader. All these changes helped to reduce machine downtime within a few months and cut the overall set-up process by an average of 45%.