Manufacturers
Lean - Setup Reduction
Increase Flexibility, Reduce Setup Times and Improve Production Flow
What is Setup Reduction?
Setup Reduction builds on the principles of the Single Minute Exchange of Dies (SMED) system, developed by Shigeo Shingo, to dramatically reduce or eliminate changeover time. The four-step Changeover Improvement Process is used to help companies design no/low cost solutions to reduce changeover time. This, in turn, allows the firm to meet customer demands for high-quality, low -cost products, delivered quickly and without the expense of excess inventory.
Benefits
* Respond to customer needs and schedules with more flexibility
* Improve on-time delivery
* Decrease costs due to excess inventory
* Increase line and machine capacity levels
* Increase changeover accuracy
* Reduce startup defects
Successes
By empowering operators to reduce make-readytime and increase run speed, a printing and publishing company decreased setup time by 30%.
A transportation equipment manufacturer implemented Total Productive Maintenance, 5-S and Cellular Flow Manufacturing approaches to its processes. As a result, setup time fell from 480 hours to 0 hours.
LE204-One-Day Workshop: Setup Reduction
Setup Reduction is part of an integrated suite of tools and services developed specifically for manufacturers. This course is one in a series of related lean courses. Use this workshop to learn the principles of Setup Reduction and the Single Minute Exchange of Dies (SMED) system. Then apply the four-step Changeover Improvement Process to achieve Setup Reduction in a life-like simulation exercise. By the end of the day you'll experience reduced costs and setup times and see machine capacity increase at the same time.
