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You are here: Home / Our Services / Continuous Improvement / Set Up Reduction

Set Up Reduction

The ability to rapidly change from one product to the next is a key to success for many companies. As customer lead times are continually shortened and product mixes become more complex, the ability to change over rapidly and easily can provide a competitive advantage. Fortunately there are powerful, quick-change techniques that can be applied to any type of operation: from metal to wood, food to plastic, etc.

Set up reduction builds on the principles of the Single Minute Exchange of Dies (SMED) system to dramatically reduce changeover time and production lot sizes, thereby improving flow. The four-step Changeover Improvement Process is used to help companies design no to low cost solutions to reduce changeover time. This allows the business to meet customer demands for high-quality, low-cost products, delivered quickly and without the expense of excess inventory. The systematic process includes analyzing a changeover, then applying quick changeover techniques and strategies to reduce the machine and/or line downtime. Standard procedures will be determined, documented, and used shift-to-shift.

Project Objectives:

  • Reduction of inventory
  • Reduction in lead-time for the product
  • Elimination of waste and non-value-added operations
  • Improvement of plant capacity
  • Increase in manufacturing flexibility
  • Improvement in quality as lot sizes and lead-times shrink
  • Improvement in cash flow through reduction of inventory and rapid conversion of raw materials into saleable product
  • Increase in competitiveness

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Success Story

Success Story
Improvements and Expansion Helps Propel the “Fairy Godmother of Fire” to New Heights

Tim and Voni Flaherty met while attending law school in Chicago and started a grand adventure that has seen them explore a variety of career opportunities. Having gone from law to banking to general management at Caterpillar, it was while living in San Antonio a few years ago that

Increased Sales
$5M
Retained Sales
$2M
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27
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  • COVID-19 Resources
    ▼
    • Main COVID page
    • Product & Services Directory
    • Critical Supply List – Manufacturing Specs
    • Cybersecurity
    • Health and Safety in the Workplace
    • Loans & Financial Resources
    • National/International Resources
    • State Resources
    • Supply Chain
  • About Us
    ▼
    • Staff and Locations
    • Board of Directors
    • Partners
    • Manufacturing Minutes Newsletter
    • Videos
    • Webinars
    • Success Stories
    • Congressional District Fact Sheets
  • Services
    ▼
    • Cybersecurity
    • Continuous Improvement
    • Technology Acceleration
    • Supplier Development
    • Sustainable Practices
    • Workforce Development
    • Online Programs
  • Events
  • Small Manufacturer’s AdvantEDGE
  • Manufacturers Connect