Set-Up Reduction Training

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 to be reconfigured to make another product into productive time. When this is achieved, many benefits are realized.

A key concept in reducing set-up time is internal vs. external activity. Internal set-up activities take place during the actual changeover when the equipment is not running. External set-up activities are done before the equipment is shut down for changeover. The more activities that can be shifted from internal to external, the more equipment uptime will be reclaimed.

Reducing the time it takes to set-up equipment increases the available capacity to make more product and leverages the investment in the machinery. 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 introduces learners to the importance of quick equipment changeover and teaches the basic tools to reduce set-up time. Participants will learn to distinguish between internal and external set-up activities and will develop skills to be able to shift internal activities to external activities. In addition, they will learn how to measure the results of their efforts and establish a system to continually monitor set-up times to hold the gains they have made.

IMPORTANT!

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.