Lean Enterprise : Set-Up Reduction

What is Set-up Reduction/Quick Changeover?

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 manufacturers to meet customer demands for high-quality, low-cost products, delivered quickly and without the expense of excess inventory.

Benefits of Set-up Reduction/Quick Changeover

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

Successes

By empowering operators to reduce make-ready time and increase run speed, a printing and publishing company decreased set-up time by 30%.

A transportation equipment manufacturer implemented Total Productive Maintenance, 5S, and Cellular Flow Manufacturing approaches to its processes. As a result, set-up time fell from 480 hours to 0 hours.