5S machine center setup

[Dont]

I've been tasked with setting up our shop 5S. Can anyone share a picture of your machining center setup?

Thanks

[Guest]

I don't have any pictures at this point as this goes back in time but.....

 

We set up each bench located at each machine, a peg board,  with almost all of the tools that you would need to set up a job....

 

Parallels

Vise stops

Soft hammer

Commonly used wrenches

Allen Wrenches

Step Block and Threaded rod sets

and a few other things.... 

 

Hangers for tools, names were added so everything had a home, you did not have to search for things

 

Every machine had multiple vises.....we used a lot of modular fixtures and most were ball locked to the table or sub-plate.....those would arrive at the machine, with the stock and the tools already set up.....

 

The setup person would place the tools into the carousel...load the vise or fixture as needed and positioned as noted....

 

The setup person would manually dial the probe over the part, location depending on part being made and hit cycle start

 

The probe would touch the top of the stock and set the work shift.....

Then the probe would set the work origin

continuing in the program, all of the tool offsets were loaded via G10

 

The first piece would run.......inspected, any adjustments made and rerun if necessary, then submitted for 1st piece.....

 

This companies average setup time went from almost 5 hours down to under 25 minutes in almost all cases.....

 

1st piece acceptance ran near 98%

[BCW]

JParis got started on some good points but got segued from 5s into better process implementation.

Sorry no pics to contribute, but I will say some of the things we have done:

• Shadow foam for all toolboxes. You could go to any box in the shop and know where everything is at, no more searching. 
• Clockwise movement for parts thru the shop. Shipping > Machining > Deburr > Marking / Plating > Shipping. Keeps everything moving, for the most part, in one direction.
• Keeping minimal stock making more room for production. Customers aren't buying your excess; get rid of it. (Red tagging)
• Floor markings, shelf marking. Everything has a spot and must be respected. Again, no more searching for things.

That pretty much covers Sort, Set in Order, and Standardize. Now you just gotta Shine it up and Sustain it!

[Guest]

JParis got started on some good points but got segued from 5s into better process implementation.

 

 

Agreed, for us at that time, one really went with the other but they are 2 different things indeed

[BCW]

I guess guess it all falls under the whole six sigma umbrella. The whole process seems to meld together in a good way when implemented correctly.