The Company
Virginia Panel Corporation (VPC) is a privately held company located in Waynesboro, VA. VPC originated as a company to manufacture patch boards for early computers that were "programmed" by making connections on patch board, similar to an old-fashioned telephone switchboard.

VPC currently manufactures interface systems for test equipment, and has about 10% of the value of a test system in the high precision test stands. VPC has in their facility, machining, plating, wiring, and wire harness manufacture.

The Problem
GENEDGE ALLIANCE hosted a set-up reduction workshop aimed at educating VPC employees on the fundamental principles of set-up reduction methodologies to reduce changeover time. The standard workshop emphasized the need to personalize training to zero in on reducing the set-up time for their CNC machining center.

The Response
GENEDGE ALLIANCE in partnership with the Shenandoah Valley Workforce Investment Board recommended the reduction of set-up time for the CNC machining center, while increasing capacity through quicker changeovers. GENEDGE ALLIANCE utilized an experienced set-up reduction team of project managers and key VPC personnel to provide on-site analysis, education and implementation of proven methodology for successful implementation of initiatives.

The Results
Set-up reduction efforts paid off with:
• 60% reduction in set-up time,
• $200,000 savings in sales value of 38 hours of machine time per week,
• $156,000 savings in the FJV-20 machine,
• and $134,000 savings in the FJV-250 machine.

Management’s Comment
" Reductions in set-up times on capital intensive automatic machining centers has allowed Virginia Panel to be much more responsive to changes in customer demand. With 80% of our business being make-to-order, it is absolutely vital that we have the ability to change from one product to another in less than 20 minutes. To do this, we have incorporated a pit crew team along with moving much of the internal set-up time to external time. Tools and fixtures are also pre-staged for quick access. Hands-on training and the involvement of our machinists was key to these successes because it promoted team awareness, involvement, and buy-in to the importance of SMED to successfully service VPC's customers. GENEDGE ALLIANCE facilitated this associate involvement through their engaging and experienced trainers," says Terry Shutter, Vice President of Engineering and Manufacturing.

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