Strategos Books & Videos

The Strategos Guide To Value Stream & Process Mapping Facilities Planning & Workplace Design

Warehouse Modernization & Planning Guide The Human Side of Lean Video

Phases of Setup Reduction

How To Reduce Setup Time

Setup reduction should be approached in four phases or stages as illustrated below. It is usually best to repeat the process through several iterations spaced several months apart.

Lean Resources

Home
Up
Resources
Site Guide
Lean Training
Book Reviews
Useful Links
Search Site
About Strategos

Roll setup

Strategos

Seminar / Kaizen

Setup Reduction

The initial phases of setup reduction (SMED) are straightforward and easy, yet often bring the greatest benefits. People are constantly amazed at how much time is wasted through disorganization and general messiness. 

Improving elements and eliminating adjustments will require more imagination, time and cost. Even here, the improvements are sometimes astonishingly simple and easy.

The "Kaizen Event" or "Blitz" is an excellent vehicle for setup reduction. It generates enthusiasm and fast results which make the efforts less mundane. For more on this, click the links at right.

Kaizen- What Does It Mean?

Is The Kaizen Blitz Right for You?

Strategos Setup Blitz

1. Maintenance, Organization and Housekeeping 

It often happens that setup problems are related to poor maintenance such as worn parts, worn tooling, dirt, or damaged threads. Disorganization and poor housekeeping are also contributors to setup problems. These are easy to fix and should be a first step.

2. Internal Elements to External 

Internal elements occur when the machine is down. Examine each internal element and see if it cannot be done externally. For example, the pre-heating of an injection molding die could be done before it goes into the machine.

More...

Part 1- Why Setup Reduction

Part 2- How To Reduce Setup Time

Part 3- Typical Results of Setup Reduction

Strategos Setup Reduction Kaizen Event

3. Improve Elements 

Here we examine every element to see how we can eliminate it, simplify it, reduce the time required or improve it in some other way.

4. Eliminate Adjustments 

Adjustments are often the most time consuming, frustrating and error prone parts of a setup. There are many ways to eliminate them entirely and this is the ultimate goal.

Why Select Strategos for Your Kaizen Event?

20+ Years Manufacturing Experience

Highly Experienced Instructors

Experts in Adult Education

 

Subscribe to Lean Briefing-- The Free Newsletter of Lean Manufacturing Strategy

First Name: Last Name: Email:

Lean Briefing is sent about every month. You may "unsubscribe" at any time.

We will NOT: Sell this information, transfer it, bombard you with Email, or otherwise abuse your trust

Home ] Resources ] Site Guide ] Lean Training ] Book Reviews ] Useful Links ] Search Site ] About Strategos ]

Email: info1@strategosinc.com          Phone: 816-931-1414

Strategos-International:  China - Europe - Australia - North America