Last modified: 2014-06-26
Abstract
A manufacturer of aluminium parts for the automotive industry is currently constrained by its forging process. Tool changes are required on the forge to produce different part types. This paper describes a project that was undertaken to reduce changeover time and improve the quality of tool changeovers. A study of current practices revealed high variability in the changeover times and showed that changeover performance could be improved by reducing the effort required to perform changeover tasks, reducing the need for making setting adjustments, removing opportunities for making errors and standardising the procedure. The design solution includes changes to tools and equipment, improvements to tool handling and fastening methods and the use of a changeover trolley. A new, standardised process is provided, focusing on task quality and not time. Changes to the organisation’s strategy, culture and performance measures are also required for improvements to be sustainable. The resulting improvements will allow more tool changes to be performed, reducing batch sizes and the amount of work in progress required in the plant, ultimately enabling the company to plan production closer to customer demand.