1. Quick Set-Up TechniqueGO
DONE
READY
External
Internal
0 SEC
10 SEC
14 SEC
GAS
H2O

2. LEAN MANUFACTURING
Concept of Reducing Cost by Identifying and Eliminating Waste Throughout the Manufacturing Process
Time Lost Changing Over a Process Is a Form of Waste.
Quick Set-up Techniques and the Related Tools Used During This Workshop Identify Wastes in a Set-up and Generate Solutions to Eliminate Those Wastes

3. Race The Journey to World Class CURRENT SET-UP TIME Gap WORLD CLASS
The Quick Set-Up Tool
Provides the Means to Move Closer
to World Class and Close the Gap
Gap
WORLD CLASS
(TEN MINUTES or LESS)

4. WHAT IS THE EFFECT OF “SLOW CHANGEOVERS”??
Inventory More than is needed
Lead Time Longer than necessary
Quality Not as good as it could be
Cost Higher than Competitors
Capacity Lower than it could be
New Business May not be able to capture

5. QUICK SET-UP TECHNIQUE
Focuses on Capacity Improvements by Reducing “Set-up” or Changeover Time of a Process/Activity
Two/Three Day Workshop Conducted at the Work Site Focusing on a Specific Set-up/Changeover
Workshop Includes Some Training of Quick Set-up Concepts and Creativity to Rid Set-up of Waste

6. QUICK SET-UP TECHNIQUE
Characteristics
Focus is on Improving Equipment Up-Time
(rather than labor efficiency)
Utilizes People to Their Fullest Capacity
(which requires Cooperation, Training & Understanding)
Requires Constant Change
(Continuous Improvement)
Goal is to run every Part Number every day

7. QUICK SET-UP TECHNIQUE
GOAL:
Decrease Set-up Time by 50%
(Short Term Goal)
Single Digit Set-up Times
(Long Term Goal)
Get Equipment Running Good Parts ASAP
Changeover Equipment More Frequently
Run Smaller Lot Sizes

8. QUICK SET-UP TECHNIQUE
Process Steps:
1. Measure Current Set-Up Times
2. Form Set-Up Reduction Team
3. Analyze Current Set-Up Method
4. Convert “Internal” Elements to “External”
5. Simplify Remaining “Internal” Elements
6. Simplify “External” Elements
7. Minimize “1st Piece” Qualification Time
8. Identify and Train Set-Up Crew
9. Apply Continuous Improvement
10. Capitalize on Set-Up Improvement

9. QUICK SET-UP TECHNIQUE
TYPICAL AGENDA

10. QUICK SET-UP TECHNIQUE
Benefits
Reduced Lot Sizes
Reduced Inventories
Improved Quality
Increased Capacity/Uptime
Improved Responsiveness
Reduced Floor Space Required
Operator Productivity Improved

11. QUICK SET-UP TECHNIQUE
Sample of Results
ORIGINAL IMMEDIATE SHORT TERM
SUPPLIER TIME IMPROVEMENT IMPROVEMENT
Supplier E 194 min min. (45%) 74 min. (62%)
(Fasteners)
Supplier E 390 min min. (74%) 60 min. (85%)
(Injection Molding)
Supplier G 170 min min. (65%) 45 min. (74%)
(Stampings)
Supplier M 72 min min. (65%) 29.5 min. (65%)
Supplier D 156 min min. (70%) 30 min. (81%)
Supplier S 75 min min. (33%) 28 min. (63%)

12. QUICK SET-UP TECHNIQUE
THE GOAL

13. PRE-TRAINING ACTIVITIES
Select Changeover to Be Studied
Select Team Members
Inform Team Members of Workshop
What Is It
When Will It Be
Why Was I Selected
Video Tape Current Set-up Prior to Workshop
Send Copy of Tape Prior to Workshop

14. PRE-TRAINING ACTIVITIES
SELECT PROJECT
Longest Set-Up Time
High Probability of Success
Bottle Neck Operation
Large Current Run Size

15. SUGGESTED TEAM MAKE-UP
PRE-TRAINING ACTIVITIES
SUGGESTED TEAM MAKE-UP
Persons Doing Set-up
Set-up Reduction Facilitator
Related Skilled Trades
Area Supervisor
Related Tool Engineer
Related Manufacturing Engineer
Outside Resources, i.e. Machine or Tool or Mat’l Supplier
4-8 PEOPLE TOTAL

16. PRE-TRAINING ACTIVITIES (CONTINUED)
VIDEO TAPE CURRENT SET-UP (Gather Data)
- Last Good Piece of Prior Part Number
- Tape “What’s Happening” at the Process (Don’t Follow Set-up Operators)
- End Taping When First Good Piece of New Part
Number Is Accepted
- Include All “Normal Delays” in Study
- Record “Clock Time” on Tape

17. OTHER TRAINING NEEDS Meeting Room - Seating for 10
VHS Player and Monitor
Overhead Projector and Screen
Chart Paper/Stand
Tablets for Participants
Clipboards
Lunch for Team Members During Workshop