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

2. WHY ARE WE HERE? Learn Definition of Quick Set-Up
Learn About Quick Set-up Techniques
Learn What Waste is Related to Set-Up
Identify Some Forms of Waste in Target Area That
May Be Able to Be Eliminated
Develop Plan to Reduce Set-up Time By
50-75% This Week.
Implement Plan ASAP
Assign Responsibility to Capture Benefits of Set-
up Improvements; i.e. Reduce Lot Sizes

3. 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

4. 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)

5. 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

6. .... Are We Competitive
in our Set Up or Change
Over Times??

7. What is the Effect of “Slow Changeovers” on this Business??

8. 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

9. 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

10. 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

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

12. QUICK SET-UP TECHNIQUE
THE GOAL

13. Reflecting on Change IT’S NOT MAGIC !!
We Want You to Discover that Reduced Set-Up Times are
not only Possible, But Can be a Reality (this week)

14. QUICK SET-UP TECHNIQUE
Definition:
A Technique to Decrease Time Required to
Set-Up or Changeover a Process or Activity.
The Focus Is to Reduce Time From Last Good Piece to Next Good Piece.

15. QUICK SET-UP TECHNIQUE
Understanding Waste
Is Anything Other than the Minimum Time to Changeover from One Part Number to Another
Part Number; including Wastes in the areas of:
Equipment Idle Time
Direct and Indirect Labor
Set-Up Scrap
Floor Space

16. QUICK SET-UP TECHNIQUE
Definition of Waste
Anything that doesn’t Add Value to the Set-Up
Process
Anything that doesn’t Help Create Conformance
to Your Customer’s Specifications
Anything that is now done while Machine is
down that could be done while machine is running

17. QUICK SET-UP TECHNIQUE
Definition of Lead Time:
Total Time Required to Complete One Unit of a Product or Service
(such as a Set-Up)
May be Specified in Days, Hours or Minutes
Lead Time
Start of
Set-Up
End of
Set-Up
(Last Good Piece)
(First Good Piece)

18. 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

19. QUICK SET-UP TECHNIQUE
Step 1: Measure Current Set-Up Times
- Establish Baseline for Improvement
- Done by People Actually Doing the Set-Up
- Record Times
- Chart Variation; i.e. Run Chart
- Post at Process

20. QUICK SET-UP TECHNIQUE
Add Up All the Time
Set-Up/Operation Times
Move/Transfer Times
First Piece Inspection/Rework Times
Tool Changes
Die/Tool Rework Times
Total = SET-UP LEAD TIME
Start of
Set-Up
End of
Set-Up
(Last Good Piece)
(First Good Piece)

21. QUICK SET-UP TECHNIQUE
Step 2: Form Set-Up Reduction Team
1. Select Project
- Longest Set-Up Time
- High Probability of Success
- Bottle Neck Operation
- Large Current Run Size
2. Select 4-8 Team Members
- Persons Doing Set-Up
- Related Skilled Trades
- Related Mfg/Tool Engineer
- Area Supervisor
- Outside Resources; i.e. Machine/Tool Supplier
3. Empower Team: Provide Resources and Support

22. QUICK SET-UP TECHNIQUE
Step 3: Analyze Current Set-Up Method
1. 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

23. QUICK SET-UP TECHNIQUE
Step 3: (Continued)
2. Team Reviews Tape
- Chart Lead-time for Set-Up Operation
- Identify and Time Each Step (using tape)
- Identify Steps as Internal or External Elements

24. QUICK SET-UP TECHNIQUE
Step 4: Convert Internal Elements to External
- Identify Set-Up Tasks which could be
Converted to External Tasks
- Team Develops Methods to “Externalize”
Internal Tasks

25. QUICK SET-UP TECHNIQUE
Nomenclature Definitions:
Internal Activities-
Set-Up Activities that must be done while
the Process is shut down.
External Elements-
Set-Up Activities that could be done while the Process is still running Previous Part.

26. QUICK SET-UP TECHNIQUE
Add Up All the Time
Set-Up/Operation Times (Internal Times)
Move/Transfer Times (External Times)
First Piece Inspection/Rework Times (Internal Times)
Tool Changes (Internal Times)
Die/Tool Rework Times (External Times)
Total = SET-UP LEAD TIME
Start of
Set-Up
End of
Set-Up
(Last Good Piece)
(First Good Piece)

27. QUICK SET-UP TECHNIQUE
Step 5: Simplify Remaining “Internal” Elements
- Apply Team Set-Up Concept
- Standardize Sizes (Dies, Tools, Fixtures, etc.)
- Provide Locating Aids
- Utilize “Quick Disconnects” where Feasible
- Eliminate Base Machine Adjustments
- Eliminate Nuts and Bolts as Fasteners
- Create Set-Up Tooling Kit; Designate Location
- Do Operations in Parallel wherever Possible
- Apply “Motion Economy”
- Mechanize Wherever Possible
- Utilize Specific Purpose Tool Cart
- Develop/Utilize Pre-Defined Process Adjustment Parameters

28. QUICK SET-UP TECHNIQUE
Step 6: Simplify “External” Elements
- Designate Specific Storage Points for all Items
Necessary for Set-Up (Apply Workplace
Organization/Visual Control Concepts)
- Move Tool/Die Storage to “Points of Use”
- Sharpen/Repair Tools/Dies During Non-Use
Periods
- Validate New/”Renewed” Tools/Dies during
Non-Use Periods
- Schedule “Support People” Ahead of Time
- Apply Concepts of “Motion Economy” as
Required

29. QUICK SET-UP TECHNIQUE
Do the Activities Have to
Be Sequential or can they
be Concurrent?
HAVE THE TEAM ASK THIS QUESTION OF EACH OF THE ACTIVITIES IDENTIFIED IN THE SETUP.
FINDING WAYS TO MAKE NECESSARY STEPS CONCURRENT SAVES TIME!

30. QUICK SET-UP TECHNIQUE
Step 7: Minimize “1st Piece” Qualification Time
- Empower Operator to Process
(Dedicated Gages, Operation)
- Add Error Proofing Devices where Applicable
- Empower Operator to Approve “1st Piece
Quality”
- Apply Concept of “Quality at the Source”
- Quality Control does not have to Buy-in
- Foreman does not have to Buy-in

31. QUICK SET-UP TECHNIQUE
Step 8: Identify and Train Set-Up Crew
1. Form Set-Up Crew
2. Train and Practice “New” Method Including
all Appropriate Safety Measures
3. Crew Writes and Posts Set-Up Instructions,
including all Appropriate Safety Measures
4. Video New Method as a “Training Aid”

32. QUICK SET-UP TECHNIQUE
Step 9: Apply Continuous Improvement
- Chart All Set-Up Duration's (Run Chart)
(Done by Set-Up Personnel)
- Post Run Chart at Process
- Apply Continuous Improvement to Each
Processes’ Set-Up

33. QUICK SET-UP TECHNIQUE
Step 10: Capitalize on Improved
Set-Up
Reduce Lot Sizes (Run Quantities)
Reduce Inventories
Changeover More Frequently