Setup Results

Industry	Equipment	Before	After	%
Assembly	Adhesive Applicator	12:09:00	0:21:00	97%
Assembly	Air Cleaner Assembly	2:00:00	0:00:00	100%
Brake Mfg	Briquette Press	1:05:00	0:12:00	82%
Brake Mfg	Drill Machine	0:35:00	0:05:00	86%
Brake Mfg	Segment Drill	12:00:00	1:12:00	90%
Cosmetics	Capper Machine	0:09:36	0:03:21	65%
Electronics	PCB Inserion-ICs	0:13:30	0:05:56	56%
Electronics	PCB Insertion-Axial	0:05:18	0:04:18	19%
Electronics	PCB Insertion-Radial	0:54:12	0:05:06	91%
Foundry	Molding Machine	0:10:00	0:06:12	38%
Metal Cutting	Casting Drill	1:00:00	0:09:00	85%
Metal Cutting	CNC MILLING	2:00:00	0:00:00	100%
Metal Cutting	FADAL HMC	1:45:00	0:15:20	85%
Metal Fab	40 Ton Press	0:48:00	0:04:00	92%
Metal Fab	750 Ton Hyd Press	2:10:00	0:42:00	68%
Metal Fab	800 Ton Press	6:00:00	0:10:00	97%
Metal Fab	Aluminum Extruder	1:09:00	0:02:12	97%
Metal Fab	Brake Press	0:37:00	0:04:00	89%
Metal Fab	Draw Press	1:30:00	1:00:00	33%
Metal Fab	Edge Trim Press	0:24:00	0:04:00	83%
Metal Fab	Pilot Change-Muffler Press	0:07:00	0:00:15	96%
Packaging	Flex Packaging Line	3:00:00	0:10:00	94%
Paper	Sheeting	0:03:00	0:00:36	80%
Pharmaceutical	Centrifuge	0:12:00	0:02:12	82%
Plastics	250 Ton Injection Molder	1:06:00	0:09:12	86%
Plastics	Injection Molder	2:30:00	0:06:00	96%
Plastics	Injection Molder	2:00:00	0:03:00	98%
Printing	Kidder 6-Color Web Press	4:20:00	1:10:00	73%
Printing	Press Make Ready	9:30:00	4:20:00	54%
Wood	Router	0:09:00	0:01:18	86%

Note: Many of these examples were taken from our own clients' experience. Others are documented in the literature on Lean Manufacturing.

Setup Reduction- Typical Results

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Part 1- Why Setup Reduction

Part 3- Typical Results of Setup Reduction