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(+)+(+)
(+)+(+) S.M.I.L.E(sm)
(+)+(+)
(+)+(+) Setup Minimization Improves Line Efficiency
(+)+(+)
(+)+(+) The Quick Changeover e-letter
(+)+(+)
(+)+(+) Published monthly by Changeover.com
(+)+(+)
(+)+(+) Written by John R Henry, CPP
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### MARCH 2004
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The Packaging Machinery Manufacturers Institute (PMMI) will be holding it's
second annual roundtable on purchasing trends for packaging machinery. I
will be serving as a panelist in the discussion on the 2004 Purchasing
Plans Study. It looks like an exciting activity and if any readers attend,
I hope you will come up and say hello.

For complete agenda and registration information visit
http://www.pmmi.org/markettrends


SOME THOUGHTS ON...

TOOLS ON THE PRODUCTION LINE

Mankind is unique among animals in that we have the ability to create and
use tools. In some ways I am like the Tim Allen's character on the TV show
"Home Improvement", I love tools. On the other hand, I spent a number of
years running a plant maintenance department and tools were a big headache.
Tools are a necessary evil. At their best, they allow us to perform tasks
we could not otherwise do. At their worst, they allow us to cause damage to
machinery in the performance of those tasks. Too often they are ignored and
provided almost as an afterthought.

When I was just a tad, my father told me "I'm not wealthy enough to buy
cheap tools." and experience has made me a believer. Good quality tools
make the job go easier and tend to instill more pride of craftsmanship.
Poor quality or worn tools can be dowright dangerous. They can be dangerous
to the equipment being worked on as poor tolerances cause them to slip,
rounding off hexes and destroying screwdriver slots. They can be dangerous
to the user. The person who has not barked their knuckles or worse when a
tool slipped probably has limited experience. Good quality tools also tend
to be ergonomically easier to use reducing the risk of repetitive motion
injuries and fatigue.

There are a number of companies producing good quality hand tools but my
first choice, both for myself personally and when I ran a maintenance
department, has always been Craftsman from Sears. Craftsman offers a
complete catalog covering virtually everthing that could be needed,
including storage chests and cabinets, they are excellent quality and they
are reasonably priced. They also come with a lifetime guarantee and Sears
will replace, without question, any broken tool. Craftsman is by no means
the only one, there are other brands that are just as good. However, I
still have most of a set of Craftsman wrenches, sockets etc that was given
to me in 1960 and I still use them on an almost daily basis.

It is not enough to start with good tools. As they wear, they must be
replaced. Screwdrivers tend to make me crazy. They will, in the course of
normal use, wear and should be replaced. Often they are not. Mechanics will
attempt to grind down the tip and they never get it right. They then go out
and suffer with the defective screwdriver, stripping out slots and making
it difficult to use any tool. Wire cutters are another tool that wears and
need to be replaced periodically. Any tool program must not only start with
good tools but must make sure that as tools are damaged or worn, they are
replaced. Ideally, with company supplied tools, there should be a no
questions asked exchange policy. The mechanic simply takes the worn tool to
the crib and it is replaced. Periodic monitoring of the tool chests will
assure that this is carried out.

Good tools in good condition are still not enough. They must be used
properly. Groove-lock pliers and Vise-Grips should NEVER be used on a nut
or bolt. They will slip, rounding off the corners. Even if they do not
slip, the design of the jaws is such that they will chew up the nut. The
use of adjustable wrenches, though not as bad, should be avoided for
similar reasons. Wrenches should not be used as hammers. Screwdrivers
should not be used as prybars. Examples of improper tool usage could go on
but I would imagine that each of you have your own pet peeves.

One reason tools my be used improperly is because the mechanic does not
have access to the correct tool or cannot find it. To be used properly,
tools need to be available and they need to be stored in an orderly manner.
There are a number of different styles of tool boxes, cases, chests and
pouches. This needs to be carefully examined and the best one selected on
the basis of size, portability, style etc. Each mechanic should have their
own tools where possible. They should also have control over the tools and
the ability to keep them locked up to prevent their loss.

To sum up, tools are too important to leave to chance. Good quality tools
must be provided or, where the mechanic supplies their own tools, required.
They must be properly stored. Of course, good tools, properly organized and
controlled goes for nought is they are not properly used. This is a
management responsibility to make sure that each mechanic is properly
trained in how to use their tools.

TIP OF THE MONTH

Actually, this month I have a "twofer", or two tips for the price of one.
Both have to do with a pet peeve of mine, which is the use of metric tools
on standard (inch) fasteners or vice versa.

In many production lines these days there will be a mix of metric and
standard machines requiring the use of both types of tools. Frequently a
metric tool will "almost" fit a standard fastener, the mechanic will try to
use it and it will slip, rounding the fastener. This is most common in
socket or "Allen" head fasteners.

I recently ran into two solutions that should help reduce this problem.

First is the use of color coded hex wrenches. I had never seen these until
I was working with a client a few weeks ago. I now find that they are a
standard catalog item from McMaster Carr and other tool suppliers. They are
standard metric "L" wrenches but are colored a distinctive blue rather than
the normal black.

The second tip, which one of the "Achieving Quick Changeover" workshop
participants had, was to put signs on each machine warning that it was
metric and to use metric tools. This is one of those ideas that is so
simple I feel embarrassed I didn't think of it 25 years ago.

But I didn't.


Best,

John R Henry CPP

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