Table 2 Effective design rules to reduce... | Emerald Publishing

Table 2

Effective design rules to reduce set-up times

Technical improvement	Design guidelines
1. Simplification	• Lighten those parts that will be moved during set-up • Eliminate the need to disassemble elements that will not be replaced • Eliminate the need to replace elements by making them modifiable • Design modular assemblies/parts • Delete pipe connections, or use quick plug connections • Facilitate easy access to the machinery or to the parts subject to set-up operations • Simplify the actions of the employees by focusing on ergonomics • Design parts following the principles of Poka-Yoke
2. Standardization	• Standardize bolts • Standardize functional dimensions of parts of machinery and equipment • Design standard machine parts
3. Quick fixing	• Use few bolt types • Use quick locking devices (one-turn, one-motion, interlocking) • Use hydraulic, pneumatic or electromagnetic locking devices
4. Optimization of adjustments	• Avoid internal placements and adjustments • Avoid manual adjustments by using simple and quick adjustment systems • Equip the machinery with appropriate centering and positioning systems • Introduce integrated measuring and control devices • Equip the machinery with discreet positioning systems • Use centering templates • Use the Least Common Multiple principle
5. Externalization	• Grant safe access to the machinery while it is operating • Introduce external buffers or duplicate parts • Use masks or intermediate bases • Integrate equipment or workbenches for early preparation
6. Mechanization	• Integrate tools for moving heavy or bulky parts • Use special tools to speed up the internal tooling phases • Mechanize machine parts for quick, non-manual set-ups

Technical improvement	Design guidelines
1. Simplification	• Lighten those parts that will be moved during set-up • Eliminate the need to disassemble elements that will not be replaced • Eliminate the need to replace elements by making them modifiable • Design modular assemblies/parts • Delete pipe connections, or use quick plug connections • Facilitate easy access to the machinery or to the parts subject to set-up operations • Simplify the actions of the employees by focusing on ergonomics • Design parts following the principles of Poka-Yoke
2. Standardization	• Standardize bolts • Standardize functional dimensions of parts of machinery and equipment • Design standard machine parts
3. Quick fixing	• Use few bolt types • Use quick locking devices (one-turn, one-motion, interlocking) • Use hydraulic, pneumatic or electromagnetic locking devices
4. Optimization of adjustments	• Avoid internal placements and adjustments • Avoid manual adjustments by using simple and quick adjustment systems • Equip the machinery with appropriate centering and positioning systems • Introduce integrated measuring and control devices • Equip the machinery with discreet positioning systems • Use centering templates • Use the Least Common Multiple principle
5. Externalization	• Grant safe access to the machinery while it is operating • Introduce external buffers or duplicate parts • Use masks or intermediate bases • Integrate equipment or workbenches for early preparation
6. Mechanization	• Integrate tools for moving heavy or bulky parts • Use special tools to speed up the internal tooling phases • Mechanize machine parts for quick, non-manual set-ups

Source(s): Authors' work