Set-up Reduction Kaizen

Set up time is the total length of time between the last good part of previous run to the first good part of the next run during this time a machine or equipment is down and not producing parts.

This can be divided into two parts:

• Internal Set up

The portion of the set up that can only be done while the machine is shut down

• External Set up

Parts of the set up that can be performed while the machine is producing the parts.

Steps for Set up Reduction Kaizen

1. Review objectives with Team and keep team members informed of all the activities for which their support and cooperation is needed.
2. Video tape the existing set up and defines each element.
3. Separate the internal and external elements of the set-up.
4. Post a set-up time bar chart with target time indicated.
5. Convert internal set up to external set-up.
6. Improve all the elemental operations, starting with internal.
7. Develop and train operators in new work sequence.