How does workshop layout affect changeover efficiency

How does workshop layout affect changeover efficiency
30% -40% of the changeover time is spent on walking and finding tools. The workshop layout is not reasonable, and even the best quick change device cannot be fully utilized.
The length of the running line determines the auxiliary time
The distance from the machine to the mold storage area, tool cabinet, and preheating furnace directly affects the auxiliary time for mold changing.
For every 20 meters increase in travel distance, it takes about 1 minute more for each round trip. A round trip of 5-8 times, which is 5-8 minutes.
Layout optimization can shorten the flow line by half and correspondingly reduce the changeover time by 10% -15%.
Location of mold storage area
The mold storage area should be close to the production area, ideally within 30 meters.
Store according to module number and cooperate with Kanban management. The mold finding time can be reduced from 20 minutes to 5 minutes.
Xinfeng Mold will reserve unified lifting holes in the mold frame design of the wheel hub mold, making it easy for customers to transport with the same set of lifting equipment.
Relative position of preheating furnace and machine
The preheating furnace is located near the machine, which can reduce the heat loss and time during the transfer of the hot mold.
It is recommended to control the time from taking out the mold from the furnace to the machine within 10 minutes. After more than 20 minutes, the mold temperature will decrease by 30-50 ℃.
The cooling of the large mold is slow, but it is still recommended to control it within 15 minutes. The transit time should be included in the standard working hours for changeover.
Fixed position management of tools and spare parts
The changeover tool should be placed on a dedicated tool cart and moved with the mold. The tools are stored centrally for easy access.
A set of spare parts is allocated according to the mold position for vulnerable parts and placed in the spare parts cabinet next to the machine. Missing parts and downtime are common reasons for delayed replacement.
The position of the tool cart should be fixed and marked. Return to your original position after each use to avoid missing it next time.
Layout of pipelines and cables
The interface positions of water, gas, and signal lines should be unified, and it is recommended to concentrate them on one side of the mold.
The pipeline runs on the overhead bridge without falling to the ground. Landing pipelines are prone to being crushed and not conducive to cleaning.
The color and number of the quick connector should correspond. The troubleshooting time for misconnection often exceeds the takeover itself.
The sequence of layout renovation
First, conduct a value stream analysis to identify the actual flow of the replacement model. Adjust the storage area and tool position again. Finally, consider equipment relocation.
The cost of equipment relocation is the highest and affects production. It can be solved by adjusting the storage area without the need to move the equipment.
Verification of layout adjustment
Verify the effect with an actual changeover timing after adjustment. If the changeover time does not decrease, it indicates that the bottleneck is not in the production line, but in the preparation of tooling or parameters.
The layout renovation should be implemented step by step, moving only one area at a time. Multiple changes were made simultaneously, resulting in issues that cannot be attributed.
Practical tips
The changeover tool cart is configured according to the mold position, with one set of molds corresponding to each cart, reducing the time spent searching for tools.
The ground is designated as a replacement operation area, and unauthorized personnel are not allowed to enter, which not only ensures safety but also reduces interference.
The workstation lighting should cover the mold storage area, and when searching for molds, it is difficult to see the number clearly, which will take more than ten minutes.
Frequently Asked Questions
Q: How much changeover time can the layout save?
Answer: Reasonable layout can reduce changeover time by 10% -15%.
Question: How far is the mold storage area from the machine?
Answer: It is recommended to cooperate with numbering management within 30 meters.
Q: How long does it take for hot mold transfer?
Answer: It is recommended to stay within 10 minutes and not exceed 15 minutes.
Question: How do I put the tools?
Answer: Use a mold tool cart and implement fixed location management.
Question: Where does the pipeline go?
Answer: Walk up the bridge and the interfaces are concentrated on one side of the mold.
Q: Should we change the layout first or replace the equipment first?
Answer: First, change the layout and storage area, as equipment relocation has the highest cost.
Recommended search keywords
Workshop layout, mold changeover efficiency, mold storage area, wheel hub mold workshop, wheel hub mold manufacturer, lean production layout, changeover flow line, tool placement management, casting workshop planning, casting mold manufacturer