Establishing a set-up reduction process is necessary to improve set-up times by removing waste from manufacturing processes.

Purpose

To define a process that will be used to systematically reduce the set-up time that is required for a product to be produced.

Who Does It?

Manufacturing managers, quality managers, and other key persons involved in the set-up process.

Time Frame

Three to six weeks to develop the process and ongoing to implement throughout the plant.

Tools and Techniques

• Detailed Process Sheet or Standardized Work Combination Table used to determine the steps involved and the amount of time it takes to complete each step in the set-up process.

• Videos of the process used to ensure all the steps are completed in order.

• Brainstorming to identify/eliminate steps in the process.

• Employee Skills Matrix used to identify a pilot team and subsequently train employees in the new set-up process.

Select a cell or area that will provide the most improvement without taking a long time to implement the change. Use the employee skills matrix to select a team comprised of four to five people, include the programmer, machine operator, tool room attendant, supervisory, etc., anyone who may add value to improving the current setup process.

Select a date and time and video tape a set-up process from start to finish. The time measurement should be from the time the last good part comes off...