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
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
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
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.