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Makeready Reduction in a Platen Die Cutting Operation: an Analysis of Process Improvement Methodologies

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Makeready Reduction in a Platen Die Cutting Operation: an Analysis of Process Improvement Methodologies Rochester Institute of Technology RIT Scholar Works Theses 2009 Makeready reduction in a platen die cutting operation: an analysis of process improvement methodologies Charles Armendariz Follow this and additional works at: https://scholarworks.rit.edu/theses Recommended Citation Armendariz, Charles, "Makeready reduction in a platen die cutting operation: an analysis of process improvement methodologies" (2009). Thesis. Rochester Institute of Technology. Accessed from This Thesis is brought to you for free and open access by RIT Scholar Works. It has been accepted for inclusion in Theses by an authorized administrator of RIT Scholar Works. For more information, please contact [email protected]. Makeready Reduction in a Platen Die Cutting Operation: An Analysis of Process Improvement Methodologies. By Charles E. Armendariz A thesis submitted in partial fulfillment of the requirements for the degree of Master of Science in the School of Print Media in the College of Imaging Arts and Sciences of the Rochester Institute of Technology Fall 2009 Primary Thesis Advisor: Dr. Scott Williams Secondary Thesis Advisor: Professor Barbara Birkett Technical Advisor: Vinnie Buonomo School of Print Media Rochester Institute of Technology Rochester, New York Certificate of Approval Makeready Reduction in a Platen Die Cutting Operation: An Analysis of Process Improvement Methodologies This is to certify that the Master’s Thesis of Charles E. Armendariz has been approved by the Thesis Committee as satisfactory for the thesis requirement for the Master of Science degree at the convocation of Fall 2009 Thesis Committee: Primary Thesis Advisor Secondary Thesis Advisor Thesis Consultant Graduate Program Coordinator Chair, SPM ii Acknowledgements First I would like to thank my heavenly Father, I believe throughout this endeavor, He provided me right happenings. I believe that God set me up to always succeed and never to fail and for that I am thankful. I would like to thank my family for all their support, love and prayers, without them, I know accomplishing this goal would not of been possible. I would also like to thank my wonderful friends and loved ones for their support and guidance during this project. I would like to thank the faculty at RIT School of Print Media for their tremendous support and guidance and to Company DP for providing me an opportunity to perform research at their company. iii Table of Contents List of Tables.......................................................................................................ix List of Figures.....................................................................................................xi List of Equations................................................................................................xii Abstract .............................................................................................................xiii Chapter 1 ..............................................................................................................1 Introduction and Problem Statement.................................................................1 Introduction ......................................................................................................1 Statement of Problem......................................................................................2 Reason for Study .............................................................................................3 Chapter 2 ..............................................................................................................5 Theoretical Basis.................................................................................................5 5S Tool (Sort, Straighten, Shine, Standardize, Sustain)...............................6 Process Standardization Tool.........................................................................7 Improve Standards .........................................................................................8 Standardization Promotes Individuality and Creativity ...................................8 Visual Control Tool ..........................................................................................9 Continuous Improvement Tool (Kaizen)........................................................9 Single-Minute Exchange of Die Technique (SMED)....................................10 iv Traditional Improvements vs. SMED Improvements ....................................11 Internal and External Activities .....................................................................12 Parallel Activities ..........................................................................................12 Elimination of Excessive Adjustments..........................................................12 F.A.S.T. ........................................................................................................13 Total Production Maintenance (TPM)...........................................................14 Total Production Maintenance (TPM) Equipment Program..........................15 Overall Equipment Effectiveness (OEE) ......................................................16 Chapter 3 ............................................................................................................19 Literature Review...............................................................................................19 Lean Manufacturing.......................................................................................19 Improvements Through Lean Leadership ....................................................20 Limitations Affecting Lean Practices in the U.S............................................21 Lean in Print Manufacturing .........................................................................23 Process Improvement ...................................................................................24 Makeready Improvements for Platen Die Cutting Operation........................26 SMED for Platen Die Cutting Operation. ......................................................27 Long-Term Implementation Difficulties for SMED. .......................................28 Improving Equipment Performance with Reliability. .................................30 Chapter 4 ............................................................................................................32 Research Statement ..........................................................................................32 v Limitation of the Study ..................................................................................32 Chapter 5 ............................................................................................................34 Description of Equipment and Process...........................................................34 Chapter 6 ............................................................................................................35 Methodology ......................................................................................................35 Machine Effectiveness Analysis...................................................................36 Kaizen Event...................................................................................................39 Kaizen Group ...............................................................................................40 Kaizen Event Schedule ................................................................................40 Kaizen Event Area Profile ............................................................................41 Kaizen Newspaper .......................................................................................41 Kaizen Blitz.....................................................................................................42 5SBlitz ..........................................................................................................42 Makeready Blitz............................................................................................43 Spaghetti-Mapping Diagram. ....................................................................44 Video Recording. ......................................................................................46 Set-up Observation Analysis Form. ..........................................................46 Data Analysis .................................................................................................47 Analysis of Machine and Process Effectiveness ..........................................47 5S Analysis...................................................................................................48 Makeready Analysis .....................................................................................48 vi Makready Checklist Form. ........................................................................48 Chapter 7 ............................................................................................................50 Results and Discussion ....................................................................................50 Machine and Process Effectiveness Analysis ............................................50 Pareto Chart .................................................................................................50 Individual X Chart .........................................................................................51 Discussion of OEE........................................................................................53 Theoretical Results. ..................................................................................53
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