Quick Changeover, as the name implies, is a system for reducing changeover and setup times. As Lean Manufacturing systems reduce lead times and quantities produced, companies must reduce the setup times. The result of less changeover time is lower cost, more flexibility, more changeovers, and competitive advantage.

The system of reducing changeovers, often called SMED (Single Minute Exchange of Die) does not require expense in purchasing automation. In fact, times are reduced through very little if any expense. Only once the times have been reduced drastically, often cut in half three or four times, would a company commit to spending on automation.

Set up time reduction employs the use of many lean manufacturing concepts in addition to proven time reduction concepts. Some of these concepts are 5S, Total Productive Maintenance (TPM), Kaizen. Setup time reduction begins with workplace organization and housekeeping. Therefore, 5S is usually implemented first. The set in order part of 5S is critical in setup reduction, as tools and materials must be located nearest the point of use and be readily available when needed.

Setup reduction concepts go much further than 5S. There are many ways of reducing setup time through detailed analysis of every single task involved in the setup. Every motion of workers and every tool or material is studied. For example, if an operator walks to retrieve a measuring instrument and then uses it to set up a part of the machine, a reduction in time is possible. The measuring instrument could be incorporated into the machine so it does not need to be retrieved or positioned for use.

Involving the experts, which is generally the long time operator on the equipment, leads to setup reduction success. Once operators and management begin to think differently and employ Lean Manufacturing concepts dramatic setup reduction times can be achieved.

Setup time reduction is imperative for Lean Manufacturing implementation. Our online course teaches setup reduction in detail and how it relates to other disciplines such as 5S, Kaizen, TPM, and continuous flow.

BPR’s lean manufacturing certification online courses can be completed at your convenience 24/7. Simply log in and begin the course. You can stop any time and come back to where you left off. Once the course is successfully completed, the certification will be mailed to you.