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Lean: Setup Reduction

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What is Lean: setup reduction?

Lean: setup reduction is the process of reducing changeover time (i.e., from the last good piece of the previous run to the first good piece of the next run). Since setup activities add no marketable form, fit, or function to the product, they are by definition non-value adding. By reducing setup time toward Single Minute Exchange of Dies (SMED), more setups can be completed each day. SMED is a systematic approach to reducing changeover times to less than ten minutes. This allows batch size reduction, which is critical for flow and improves manufacturing flexibility.

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What are the benefits of Lean: setup reduction?

Implementation of Lean: setup reduction will help

  • reduce batch size, leading to increased frequency of production for each model.
  • reduce lead time, resulting in improved delivery.
  • improve documentation of setup processes, leading to improved quality.
  • decrease inventory and costs, while increasing capacity.

What can CIRAS do for my company?

CIRAS can provide a Lean expert to facilitate Lean: setup reduction for a team of company members including both management and production workers.

What is my next step?

Contact these staff members to see what CIRAS can do for you.