Setup reductions are a key component in an improvement process. There are different ways to attack this area. Some will use a Kaizen event to get a larger group of individuals to take a look at it. After all, the more people the more ideas that will come. No matter how you decide to take on the daunting task of setup reductions, you need to document the existing state of the setup. One way is to use a Setup Reduction Process Map.
All you are basically doing with this map is to draw a rough sketch of the equipment. Then, track the operators movements throughout the setup process. Draw a number with a circle around it for each required step. Do not make any comments or suggestions. Remember, you are just trying to figure out the current state of the process.
Here is a quick video showing one way to make use of this form:
Feel free to grab a free copy of our Setup Reduction Process Map below.
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This form is in PDF format
Hi
It’s very useful material for introducing new way and method of thinking about set up reduction, we can add that to prevent such wast in motion and movement through setting up process we should first setting well structured layout and a a value stream process map for the process of set up to avoid waste in movement, in the mentioned set up reduction vedio we didn’t talke about tools movement and other equipments that might used in machine set up. Also we didn’t figure out what we can do with emergencies stoppages, but really it’s a great video
Thanks
Ahmed Hussein
Lean Thinker
process map is the most powerful tool i have use for all the improvement to i have worked on…you can explain to your upper management where do they need to focus all the resources availables to meet customer ratings.
Supervisors must know this tool very well if you want to be sucessful on this.
Regards,