Setup Reductions and Workflow Improvements

A setup, or changeover, is the time between the last good piece off of the current batch of parts and the first good piece off of the next. Reducing setup times (machine or service downtime) is a prerequisite to the reduction of batch sizes in order to reduce lead times and become more responsive to customer needs. WE Inc. conducts a structured approach to setup reduction and uses SMED (Single-Minute-Exchange-of Die) principles. By eliminating some tasks, setting priorities and organizing other tasks, SMED can reduce setup times from hours to minutes.

This course is often mistaken to be for manufacturing settings only when it is actually also an excellent course for office settings. Consider an example of Fox Valley Workforce Development Board's FVHCA - (Fox Valley Health Care Alliance). FVHCA coordinated the efforts of many organizations and agencies working together with different forms and standards to generate a single standard process and electronic application form that is now utilized by all FVHCA members. This standardization of workflow resulted in a 50-80% reduction in labor process time as well as the elimination of materials cost, (print & paper).

*Please note that this course requires event preparation work that must be completed prior to course start.

Day	Setup Reductions/Workflow Improvements Course Outline
ONE	1. Video existing changeover & setup activities
	2. Review tapes for waste identification
	3. Helper/leader project report out "What's in it for me?" and set event goals
	4. Review of customer satisfaction and waste elimination
	5. SMED basics - (Single-Minute-Exchange-of-Die)
	6. Eight steps to quick changeovers
	7. Review 5S - Sort, Straighten, Sweep, Standardize & Sustain
	8. Implement Sort, Straighten, & Sweep
	9. Using forms to organize observations
	10. Review setup video
TWO	1. Analyze existing setup
	2. Review task sequences
	3. Develop and standardize improvements
	4. Assign improvement tasks
	5. Convert internal to external
	6. Devise further improvements
	7. Run new setup
	8. Review before the next event: What went well? What went badly? What changes are needed?
THREE	1. Run final setup with changes
	2. Document and formalize new setup
	3. Student teach back - Review key learning elements & understanding
	4. Report out to management / organization
	6. Post Setup Reductions / Workflow Improvements results in a public area

 

Contact

For more information, please contact our LEAN Team via:

Phone: (920) 720-5600, or

Email: leanteam@fvwdb.com