Set‐up time reduction and mistake proofing methods: an examination in precision component manufacturing

The purpose of the study reported in this paper was to examine how manufacturing organisations used set‐up time reduction and mistake proofing methods. The study was conducted in companies involved in manufacturing precision components. It was found that the companies were approaching the application of these concepts mainly through traditional work‐study type methods rather than using Shingo’s single minute exchange of die and poka‐yoke or mistake proofing methodologies. There was clear evidence that the four companies are reducing set‐up time through supporting mechanisms such as kaizen teams. The main poka‐yoke devices used were jigs, gauges, pegs, lights and buzzers. Total productive maintenance, suggestion schemes and quality management tools and techniques were also employed to reduce set‐up times and mistake proof processes. The main barriers to the application of these methods include traditional methods of working and resistance to change.