Setup Reduction

Reduce product lead times and improve manufacturing capacity

This half day session, designed for associates at all levels in the organization, addresses the need for faster setup times in the manufacturing process.  Reducing setup times increases production capacity and improves customer satisfaction without adding resources and increasing costs.

Pre-requisite: Lean Overview must be taken prior to attending Setup Reduction.

Course Content Includes: 

  • Why achieving reduced setup times are essential in a Lean enterprise
  • How setup reduction reduces waste
  • Traditional setups versus Lean setups
  • Definition of setup time
  • The two types of setup elements
  • The goals of setup reduction
  • The impact of 5S on setup times
  • Six steps for reducing setup times

 Upon completion of the Setup Reduction session, participants will be able to: 

  • Define the setup reduction process
  • Identify opportunity areas for setup reduction
  • Define the impact of setup reduction on waste
  • Understand how lead times are reduced through setup reduction
  • Recognize the specific types of setup waste
  • Define who should be on the setup reduction team
  • Execute the setup reduction process
  • Apply continuous improvements to the setup reduction process