Archive for Set-Up Reduction

Set-Up Reduction: What can we learn from a pit crew?

What are slow changeovers costing your business?

NASCAR driver Kevin Harvick says that a slow changeover by his pit crew cost him the Southern 500.

Auto racing, both NASCAR and Formula 1, have reduced the time it takes to change tires and fuel the vehicle (NASCAR refuels, Formula 1 drivers are not allowed to refuel) from minutes to a matter of seconds. Here is a video Read More

Set-Up Reduction Basics Training

Course Outline
Course Objectives

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.

You May Also Be Interested In…

  • 5S’s: Workplace Organization – Comprehensive training in the concepts and application of the 5S’s (Sort, Set in Order, Shine, Standardize and Sustain) and how to apply these techniques on the job.
  • Lean Manufacturing – Online training that provides learners with a comprehensive understanding of how Lean Manufacturing works in a manufacturing environment.
  • Mistake-Proofing Training – Comprehensive online training in poka yoke/mistake-proofing techniques for manufacturing operations.

This Course is Derived from Lean for Job Shops

This course is a great way to learn about set-up reduction.  It is taken from our comprehensive Lean for Job Shops course.  If you have already taken the Lean for Job Shops course, you have already seen the content covered in Set-Up Reduction.

Set-Up Reduction Basics Course Outline

Lesson 1 | Set-Up Reduction Background

  • What is set-up reduction?
  • What are the benefits of set-up reduction?
  • How do ineffective set-up practices contribute to the “Seven Wastes” especially in the Overproduction, Inventory and Waiting categories.

Lesson 2 | Five Steps for Faster Set-Ups

  • Be Prepared
  • Combine or Eliminate Tasks
  • Optimize Tools and Fasteners
  • Train, then Practice
  • Monitor Performance
  • (… and then repeat.)

Challenge

  • An assessment of the learner’s progress in this course.

Set-Up Reduction Basics Course Objectives

  • 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.

Set-Up Reduction Basics Course Outline

Lesson 1 | Set-Up Reduction Background

  • What is set-up reduction?
  • What are the benefits of set-up reduction?
  • How do ineffective set-up practices contribute to the "Seven Wastes" especially in the Overproduction, Inventory and Waiting categories.

Lesson 2 | Five Steps for Faster Set-Ups

  • Be Prepared
  • Combine or Eliminate Tasks
  • Optimize Tools and Fasteners
  • Train, then Practice
  • Monitor Performance
  • (... and then repeat.)

Challenge

  • An assessment of the learner's progress in this course.

Set-Up Reduction Basics Course Objectives

  • 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.