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.