
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.