Setup Reduction/ Quick Changeover

House of Lean

Setup Reduction/ Quick Changeover builds on the Single Minute Exchange of Dies (SMED) system. This methodology dramatically reduces machine changeover, which is calculated as the time duration from the last good part of Component A to the first good part of Component B. The effective use of this system provides increased flexibility to the manufacturing process. Numerous short production runs can be completed in the same time frame as a single long run that produces excess inventory of one part and insufficient quantities of other parts. The result is an increased ability to meet multiple customer demands, increase on-time delivery, reduce WIP and accelerate inventory turns. Furthermore, these improvements can normally be realized with no or limited investment in equipment or tooling.

Setup reduction/ quick changeover is a four-step process designed to reduce average changeover time by 50% or more on the first iteration. It also lends itself to continuous improvement for even further time reductions in the future. The specific steps in the process are as follows:

• A joint team of Insyte Consulting and company personnel is established to address the changeover issue. A specific machine or job is selected for setup reduction. The changeover is conducted using the accepted methodology in place. However, the setup is actually timed and video taped so that a baseline is established and the actual changeover can be thoroughly analyzed.
• The video tape is reviewed and analyzed by the joint team. Activities are broken down as internal (actual time spent doing the changeover) and external (related activities like going for required molds, tooling, etc.) that together make up the full time duration. 
• The results are reviewed with the group so that changeover goals and a methodology can be established. Changeover observation charts are used to categorize three changeover elements (preparation, removal/ installation, trial run / adjustments) and prioritize improvement suggestions. The team will subsequently develop a detailed setup analysis chart with the identified improvements and procedures.
• The final step is to conduct the changeover using the agreed upon process and measure the improvements realized. This information can also be used for future efforts to further reduce set up times.

Insyte Consulting has Western New York's largest and most diverse staff of Lean Six Sigma (LSS) manufacturing experts—all with extensive hands-on, industry experience. We have helped WNY companies improve operations using lean manufacturing methodologies for over twenty-five years. Insyte has worked successfully with more WNY companies using these techniques than any other consulting organization. We welcome the opportunity to discuss your specific situation and how we may contribute to your improved competitiveness and profitability using proven lean manufacturing tools.

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