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Set-Up Reduction Basics


Intended Audience 

Operators, process engineers, maintenance personnel,  and manufacturing managers and supervisors.

Time To Complete

1.5 hours (0.2 CEUs)

What is Set-Up Reduction?

Perhaps one of the most important yet underappreciated aspects of lean is reducing the time to set-up or changeover processes from one product to another. Whenever process equipment is being "set-up" or "changed-over" to make the next part, it is not productive and "waste" is incurred. Reducing set-up time converts time equipment is shutdown being reconfigured to make another product into productive time. When this is achieved, many benefits are realized.

Reducing the time it takes to set-up equipment increases the available capacity to make more product. If you can "sell the capacity" that becomes available, there is a direct benefit to the bottom line. Reduced set-up times lead to greater operational flexibility providing the ability to respond quickly to customer needs.

Set-Up Reduction Basics Online Training

Set-Up Reduction Basics introduces learners to the importance of quick equipment changeover and teaches the basic tools to reduce set-up time.

This Training Enables Learners To...

  • Describe the purpose and benefits of reducing set-up time.
  • Show the relationship between the Seven Wastes and Set-Up Reduction.
  • Identify the key components of set-up reduction and explain the role each plays in reducing set-up time.
  • Explain the difference between internal and external set-up time.
  • Identify opportunities to:
    • Convert internal set-up tasks to external ones.
    • Combine or eliminate set-up activities.
    • Reduce travel and motion.
    • Use portable set-up carts.
    • Minimize the use of tools and optimize the use of fasteners.
    • Monitor and subsequently improve performance.

Recommended Prerequisites

  • None.

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  • Lean Manufacturing - Online training that provides learners with a comprehensive understanding of how Lean Manufacturing works in a manufacturing environment.

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