Setup Reduction

At many operations, setup reduction is a key tool for establishing work flow. Use this course to develop a pit crew in your organization that can execute standardized, rapid, low-variability setups that insure process readiness and production quality. Hand’s-on exercises where setup procedures are developed and documented insure student engagement. Typical duration for this class is 1 ½ days. Complement the classroom learning by getting ILS personnel to lead the class in a setup reduction activity in your plant. Such a facilitated activity enhances the learning, insures capability of the team to apply what they have learned across your operations, and provides immediate return on your training investment.

This course is strongly recommended for a team of individuals charged with development of rapid changeover procedures and execution of those procedures in the work place. This might, for example, include a mix of setup operators, process operators, maintenance personnel, production engineers, operations supervisors, and tooling specialists.

Students who take this class will learn…

• Prioritizing the focus of setup reduction activities in your plant in order to have maximum impact
• Foundational concepts, including internal versus external activities and the importance of variability reduction
• Documentation and analysis of the current state method
• Development of standardized external operations including 5S to support setup, readiness verification systems, and the use of setup carts and pre-positioning systems
• Strategies to convert internal to external operations including rapid transitioning of machine operating parameters, functional analysis, standardized interfacing, tool presetting, principles fixture design for rapid changeover, and gauging systems
• Tooling analysis as a method for defining setup families and optimum run sequences, including the effective use of preferred run sequences for processes under pull production control
• Design of rapid disconnect methods
• Procedures to eliminate or minimize process adjustment, including the use of design of experiments
• Design of parallel work activities in order to reduce internal downtime
• Coordination of a setup reduction event
• Documentation of standardized setup procedures, including concurrent activities
• Sustaining and continuously improving setup procedures, including the use of auditing systems and setup control boards