How do you overcome the common barriers and pitfalls of setup reduction in your operations?

1 Identify the setup steps

The first step to reduce setup time is to identify all the steps involved in changing from one product or process to another. You can use a video camera, a stopwatch, or a checklist to record the setup activities and their durations. Then, you can classify the setup steps into two categories: internal and external. Internal steps are those that can only be done when the machine or equipment is stopped, while external steps are those that can be done before or after the setup. For example, internal steps may include adjusting the machine settings, loading the materials, or testing the quality, while external steps may include preparing the tools, transporting the materials, or cleaning the work area.

3 Convert internal steps to external steps

The third step to reduce setup time is to convert some of the internal steps to external steps, if possible. This means that you should try to modify the machine or equipment, the product design, or the setup procedure to make some of the internal steps easier or faster to perform, or to eliminate them altogether. For example, you can use standardized or interchangeable parts, quick-release clamps, pre-set gauges, or color-coded labels to simplify the adjustment, loading, or testing of the machine or equipment.

4 Streamline and optimize the remaining steps

The fourth step to reduce setup time is to streamline and optimize the remaining steps, both internal and external. This means that you should try to eliminate any waste, variation, or error in the setup process, and improve the efficiency and effectiveness of each step. For example, you can use 5S (Sort, Set in Order, Shine, Standardize, Sustain) to organize and maintain your work area, tools, and materials, or use visual aids, checklists, or standard operating procedures to guide and monitor the setup process. You can also use team-based approaches, such as parallel processing, cross-training, or kaizen events, to involve and empower your workers in the setup reduction efforts.

5 Measure and monitor the setup performance

The fifth step to reduce setup time is to measure and monitor the setup performance, and compare it with your goals and benchmarks. This means that you should track and analyze the setup time, frequency, quality, and cost of each product or process, and identify any gaps or opportunities for improvement. You can use tools such as charts, graphs, dashboards, or scorecards to visualize and communicate the setup performance data, and use methods such as PDCA (Plan-Do-Check-Act) or DMAIC (Define-Measure-Analyze-Improve-Control) to implement and sustain the improvement actions.

6 Continuously improve the setup process

The sixth and final step to reduce setup time is to continuously improve the setup process, and adapt it to the changing customer needs and market conditions. This means that you should not settle for a one-time improvement, but rather seek for ongoing improvement and innovation in your setup process. You can do this by encouraging a culture of continuous learning and experimentation, by soliciting feedback and suggestions from your customers, suppliers, and workers, and by benchmarking and learning from best practices in your industry or other industries.