Head & base production optimization : setup time reduction

Abstract

At Schlumberger, the make-to-order strategy and number of Head & Base product types (about 1000 types) requires a flexible manufacturing system in which the machine setup is frequent. However, the lengthy CNC machine setup time in the Head & Base machining station directly affects the manufacturing capacity. This research implements Single Minute Exchange of Die (SMED) methodology and proposes a set of solutions, such as manufacturing sequence optimization, setup sequence optimization, setup operation simplification, etc, to reduce setup time without sacrificing quality. Most of the solutions have been implemented and the result is significant and impressive, the overall setup time has been reduced by up to 40 percent and the expected cost saving is about 50,000 USD.