Setup Reduction
Lean Manufacturing focuses a company on eliminating waste and increasing
production flexibility, making quick machine changeover and setup reduction a
requirement. At Sterling, we consider Quick Changeover to be one of the most
important components of a Lean Initiative.
THE WORKSHOP
This one-day workshop will give you
the knowledge required to systematically review your current setup operations and
eliminate wasted effort and material. Applying these techniques, most companies see a decrease in setup
time of 50 to 75%.
In this workshop, we will review the concepts of
Lean Setup Reduction. We will engage in a number of practical exercises in which
the class will analyze a videotaped setup and develop a Lean process to replace the
current operation. We will also look at the effects of setup issues on quality
and lot sizing.
Attendees will be requested to review some course materials
prior to the workshop. Details will be included in the registration confirmation
package.
LEARNING OBJECTIVES
 |
The fundamental principles of Lean
Setup Reduction |
|
Selecting and training a Setup
Reduction Team |
|
Selecting the most effective setup
reduction projects
|
Calculating the costs of a
current setup and the benefits of a reduction program |
|
Calculating current and future
production lots sizes |
|
|
Three methods of analyzing current
setups and when to use each |
|
Identifying waste in a setup |
|
Low cost waste reduction methods |
|
Implementing a reduced setup
process |
|
Measuring the results of a Lean
setup |
This workshop is available as an
in-house workshop at your company. We will videotape a setup in your plant and
work with your team to analyze and reduce the setup and implement the new Lean
process. Contact us for information about scheduling
an in-house workshop.
Click
here to check for open workshop dates or to register
"Your workshop was
excellent. Our setup reduction team has analyzed 14 of our most repeated
setups and reduced each by more than 50%. This will result in an increase in
production of over $185,000/year and has helped us cut our leadtimes by almost
20%." - Richard Barker, Manufacturing Engineering Manager
