| 1 – What is Set-up Reduction?
Set-up Reduction builds on the principles of the Single Minute Exchange of Dies (SMED) system, developed by Shigeo Shingo, to dramatically reduce or eliminate changeover time. The four-step Changeover Improvement Process is used to help companies design no/low cost solutions to reduce changeover time. This, in turn, allows the firm to meet customer demands for high-quality, low-cost products, delivered quickly and without the expense of excess inventory.
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3 – Successes
By empowering operators to reduce make-ready time and increase run speed, a printing and publishing company decreased set-up by 30%.
A transportation equipment manufacturer implemented Total Productive Maintenance, 5-S, and Cellular Flow Manufacturing approaches to its processes. As a result, setup time fell from 480 hours to 0 hours.
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2 – Benefits
- Respond to customer needs and schedules with more flexibility
- Improve on-time delivery
- Decrease costs due to excess inventory
- Increase line and machine capacity levels
- Increase changeover accuracy
- Reduce startup defects
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4 – Course Description
LE204 – Half Day Workshop: Set-up Reduction
Use this workshop to learn the principles of Set-up Reduction and the Single Minute Exchange of Dies (SMED) system.
Then apply the four-step Changeover Improvement Process to achieve Set-up Reduction in a life-like simulation exercise.
By the end of the day you’ll experience reduced costs and setup times and see machine capacity increase at the same time.
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