Setup Reduction Kaizen
Setup Reduction Kaizen events concentrate on reducing
the overall setup time for a family of parts or work
centers. Participants learn to apply a disciplined four-step
method to attack each source of waste in the entire
setup to achieve dramatic reductions in overall setup
time. Typical follow-on activities include batch size
reduction efforts (and the associated WIP inventory
and manufacturing cycle time improvements) that are
allowed by the capacity freed-up during the workshop.
Typical results:
- 25-80% reduction in setup times
- 25-80% reduction in batch sizes and/or additional
capacity
- Typical setup times are reduced 50-70%, which has
freed up capacity for batch size reductions and/or
additional throughput.
- Reductions in setup time have allowed the same percentage
reductions in batch sizes, and have reduced overtime.
- In addition, typical setup reduction workshops lead
to reduced quality costs due to smaller batch sizes.
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