Set up Reduction (aka Quick Changeover)

Long changeover times are the root of all evil in an equipment-intensive operation but don’t be fooled even assembly operations have changed over. This workshop will introduce a proven 5-step process to reduce changeover time. (Set Up Reduction is also often referred to as SMED = Single Minute Exchange of Dies.)

Learn how long changeovers lead to bad behavior such as:

• Overproduction - making more than needed to amortize the cost of long changeovers
• Batching - grouping similar parts together to increase the lot and limit the number of long changeovers
• Re-sequencing the work - changing the schedule to limit the number of time-consuming changeovers and make it easier for the operator.

Learn why these traditional countermeasures don’t solve the problem. They create more problems in the form of missing parts (the ones you need) and inventory (the ones you don't need). They lead to poor quality, longer lead times and poor on-time delivery, and higher costs, which in turn leads to unhappy customers. Sound familiar?

Set-up Reduction is a key strategy for achieving Just in Time (JIT). JIT is a system that aims to “make what customers want when they want it and in the quantity they want.” Reducing changeovers moves you closer to JIT as it increases flexibility to meet customer demand. It also eliminates headaches and frustrations. Learn how Setup Time is defined and measured and learn techniques to reduce it on your equipment!