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OUR SPECIALTIES: MACHINE SET-UP REDUCTION

Set-up reduction is a Lean tool used by all world-class organizations to identify and eliminate waste. Waste can reside in machine, equipment, assembly or administrative changeover processes. Set-up reduction is a simple tool that generally yields a 30-60% reduction in downtime with little to no capital investments.

Once you have an understanding of a "set-up reduction" tool and realize the power behind it, the final step is to standardize the process. This will ensure that all operators are performing the changeover properly and using the current best practice that yields the shortest downtime. The steps for achieving Set up reduction and standardization are as follows:

1. Set up reduction training to include benefits, purpose, internal activity, external activity, non- value added activity and single minute exchange of die.
2. Observe and videotape a current changeover process.
3. Analyze the current changeover process; identify process steps and times.
4. Measure external activities vs. internal activities vs. non-value added activities.
5. Design a new set-up process and evaluate improvements and performance.
6. Implement changes to reduce or eliminate external and NVA.
7. Re-videotape the new changeover process.
8. Re-analyze the new changeover process; identify process steps and times.
9. Re-measure external activities vs. internal activities vs. non-value added activities.
10. Photograph the changeover in detailed steps for standardization.
11. Copy all photos to a useable form, and print black & white copies.
12. Have operators write there own works for each photo.
13. Add text to photos, and reprint in black & white.
14. Verify all photo’s and text are correct by following the change-over guide.
15. Finalize the change-over guide, print in color and laminate.

 

 

>Click on a process below to read more about our individual specialties:

Performance measurements Value stream mapping Simulation training Kanban material replenish 5S Set-up reduction Baseline & benchmarking

Cellular manufacturing Root cause analysis Standardized work Visual factory Kaizen Process mapping Best practices