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Setup
Reduction
A Concept Book by
Accenture
Setup Reduction
A Concept Book by Accenture
Introduction
Organize the Setup Reduction Effort
Capture the Current Setup
Separate Preparation Activities from Execution Activities
Reduce Setup Execution Time
Implement the Revised Setup
Introduction
To be successful at setup
reduction, you need to see
setup for what it is
non-productive and costly.
When you are setting up you
are not doing productive work.
It is true that setups are hard
work and require skill, and that
they are necessary. But when
you consider that long setups
tie up capital, influence the
price of the product or service,
and keep you from having the
flexibility needed to meet
customer demands, the cost is
much larger than you might
initially think.
Setup Reduction
Introduction
Introduction
Organize the Setup Reduction Effort
Capture the Current Setup
Separate Preparation Activities from Execution Activities
Reduce Setup Execution Time
Implement the Revised Setup
Benefits
Companies who are
successful in reducing setup
times:
F Improve quality by
simplifying and
standardizing operating
parameters and equipment
settings
F Reduce inventory by
producing small lots
according to customer
orders
F Reduce scrap
F Satisfy customers with short
lead times and quality
products
Setup Reduction
Introduction
Insights
To survive in todays
market, it is necessary
to focus on the
customer and quickly
produce products or
deliver services that are
in demand. To
accomplish this type of
responsiveness, you
have to reduce or
eliminate the time spent
on setup tasks.
Shorter changeover
times means the
shop can offer a
greater variety of
donuts.
Producing in the
appropriate size
batches means the
donuts will be
fresher.
A greater variety of
fresh donuts
satisfies the
customers and
keeps them coming
back!
Introduction
Organize the Setup Reduction Effort
Capture the Current Setup
Separate Preparation Activities from Execution Activities
Reduce Setup Execution Time
Implement the Revised Setup
Summary
To reduce setup:
Organize the setup reduction effort.
Capture the current setup.
Separate setup preparation activities from setup execution
activities.
Reduce setup execution time.
Implement the revised setup procedures.
Reducing setup is not just a matter of improving the setup; it is a
matter of finding new ways to reduce the time setups take. All setup
reduction efforts have to start somewhere, and the next chapter,
Organize the Setup Reduction Effort, helps you understand how to
get started.
Setup Reduction
Introduction
Introduction
Organize the Setup Reduction Effort
Capture the Current Setup
Separate Preparation Activities from Execution Activities
Reduce Setup Execution Time
Implement the Revised Setup
Organize the
Setup
Reduction
Effort
Set Up Reduction
necessary.
3. Establish a team.
4. Identify and provide resources.
Benefits
F Preparing for the setup
reduction effort will increase
the probability and
magnitude of success.
Introduction
Organize the Setup Reduction Effort
Capture the Current Setup
Separate Preparation Activities from Execution Activities
Reduce Setup Execution Time
Implement the Revised Setup
Strategies
Draft a Game Plan
If you are considering making
the effort to reduce setups,
you should have an idea of
how your organization could
benefit by reducing the
non-productive time required
to change from one productive
activity to another.
In a production process, you
will need to take a high level
look at how things flow in your
operation. Map out the
processes and determine
where long setups impact the
customer response time, the
capacity of key equipment, or
the available time for
associates to perform
productive tasks. This will help
you to prioritize your setup
reduction effort.
reduce customer
response time
improve customer
experience
Set Up Reduction
Form a team
Potential Members
Fresh Perspective
Setup workers
Budget
Operators
Maintenance workers
Production supervisors
Process engineers
Operational engineers
Managers
Industrial engineers
Safety engineers
Quality Control
professionals
Action Log
Keep track of actions,
assignments, and
accomplishments of the team.
This serves as a record of
progress and a training tool to
get new members up to speed
on what has been done.
Decision-Making Authority
10
Introduction
Organize the Setup Reduction Effort
Capture the Current Setup
Separate Preparation Activities from Execution Activities
Reduce Setup Execution Time
Implement the Revised Setup
Provide Resources
Time
Tools
Set Up Reduction
11
Insights
Reducing setup times
without looking at the
big picture may not
impact the bottom line
at all. Make sure you
know why you are
reducing setup times
and how this will impact
the organization.
12
Introduction
Organize the Setup Reduction Effort
Capture the Current Setup
Separate Preparation Activities from Execution Activities
Reduce Setup Execution Time
Implement the Revised Setup
Summary
There are some specific steps that you can take to organize your
setup reduction effort:
Draft a game plan.
Identify why the setup reduction effort is necessary.
Establish a team.
Identify and provide resources.
By following these basic steps, you will provide a solid foundation for
the success of your setup reduction program. With the team in place,
the next step is to gain a full understanding of the current setup and
begin to analyze each task.
Set Up Reduction
13
14
Introduction
Organize the Setup Reduction Effort
Capture the Current Setup
Separate Preparation Activities from Execution Activities
Reduce Setup Execution Time
Implement the Revised Setup
Capture the
Current Setup
Setup Reduction
15
Benefits
F Producing documentation is
a natural path to generating
ideas, gaining involvement,
and identifying
opportunities.
16
Strategies
Document the Current
Setup
Video Record
The race is over, the
checkered flag has dropped,
and the race team is taking a
breather. No matter what
position they finished in, there
is still one more thing to do:
review the video record of the
pit crews performance that
day. Each stop has been
captured and will be reviewed
to refine performance.
Video recording is one of the
simplest and most thorough
ways to capture the work
involved in a setup operation.
It allows the team to watch
and discuss the setup work in
a meeting room. As they
watch, they can record each
step of the task.
Start by planning the setup
that will be video recorded.
Make sure the conditions are
normal and nothing unusual is
occurring. The person
performing the setup should
be part of the setup reduction
team if possible and willing to
perform the setup as usual
and not be concerned about
the usual problems that crop
up. Then video record the
entire setup operation,
showing all activities. Use the
camera's clock feature or
digital counter to provide a
running time. Finally, review
Introduction
Organize the Setup Reduction Effort
Capture the Current Setup
Separate Preparation Activities from Execution Activities
Reduce Setup Execution Time
Implement the Revised Setup
Understand and
Analyze the Current
Setup
Setup Reduction
17
Insights
Don't just jump in and
18
Introduction
Organize the Setup Reduction Effort
Capture the Current Setup
Separate Preparation Activities from Execution Activities
Reduce Setup Execution Time
Implement the Revised Setup
Summary
As you begin to capture the current setup:
Document the current setup.
Setup Reduction
19
20
Introduction
Organize the Setup Reduction Effort
Capture the Current Setup
Separate Preparation Activities from Execution Activities
Reduce Setup Execution Time
Implement the Revised Setup
Separate
Preparation
Activities from
Execution
Activities
Setup Reduction
21
22
Introduction
Organize the Setup Reduction Effort
Capture the Current Setup
Separate Preparation Activities from Execution Activities
Reduce Setup Execution Time
Implement the Revised Setup
Benefits
F Often you can reduce the
time for setup execution
significantly by simply
performing the setup
preparation activities before
or after the actual setup
execution. This reduction in
setup downtime can be
achieved quickly and with
minimum cost.
F Preparing in advance
ensures that nothing is
overlooked.
Setup Reduction
23
Strategies
In the world of professional
auto racing, every second
counts. This is evident as you
observe a crew preparing so
they can have the fastest pit
stops possible. In order to gain
a competitive advantage, all of
the preparation and even the
follow-up activities are planned
and performed in outside of
the time the car is actually in
the pit.
Make a time line showing all the activities involved in the setup.
Ask yourself, does this task need to be done here or could it be done while production is
still happening?
Distinguish Preparation
Activities from
Execution Activities
that all tools are available,
Optimize Setup
Use your analysis of the setup Preparation Activities
equipment is functioning, and
Organize Setup
Preparation Tasks
Checklist
Once you have determine
what can be done outside of
the setup execution, begin the
plan to streamline and
mistake-proof the preparation
activities.
24
Introduction
Organize the Setup Reduction Effort
Capture the Current Setup
Separate Preparation Activities from Execution Activities
Reduce Setup Execution Time
Implement the Revised Setup
Setup Reduction
25
Insights
Working families have
precious few moments to
prepare a meal on
weekday evenings. How
can these ideas about
preparing in advance be
used to reduce the setup
time for getting a healthy
meal on the table?
Prepare in advance for
meal execution!
Make a checklist of
items to keep on hand
(use for shopping for
key ingredients).
Keep all necessary
utensils, pots, and
spices close at hand
(cart) and in specific
'homes' (5-S).
Remove all clutter and
distractions from the
kitchen to eliminate
wasted time (5-S).
26
Prepare ingredients in
advance and freeze
(meal kit).
Purchase
pre-packaged foods.
Introduction
Organize the Setup Reduction Effort
Capture the Current Setup
Separate Preparation Activities from Execution Activities
Reduce Setup Execution Time
Implement the Revised Setup
Summary
You can greatly reduce the amount of time required for a setup by
identifying tasks that can be performed before equipment is taken
off-line, or after it is running again. In addition, you can streamline the
setup preparation activities to reduce the overall time and cost for
setup. To do this:
Distinguish preparation activities from execution activities.
Optimize setup preparation activities.
Organize setup preparation activities.
Next, you need to review the time used for setup execution and
identify ways to shrink that time to a minimum. The next chapter,
Reduce Setup Execution Time reviews these concepts.
Setup Reduction
27
28
Introduction
Organize the Setup Reduction Effort
Capture the Current Setup
Separate Preparation Activities from Execution Activities
Reduce Setup Execution Time
Implement the Revised Setup
Every task is coordinated with the other tasks and takes the
least amount of time possible.
Reduce Setup
Execution Time
Setup Reduction
29
Benefits
F Reducing the time it takes for
setup execution directly
impacts uptime, flexibility,
and capacity.
30
Introduction
Organize the Setup Reduction Effort
Capture the Current Setup
Separate Preparation Activities from Execution Activities
Reduce Setup Execution Time
Implement the Revised Setup
Strategies
Two tires on one side. Two teams working at the same time.
Setup Reduction
31
Prepare Conditions in
Advance
Each tool or piece of
equipment used during a pit
stop must be performing at
peak efficiency. Great care is
taken to ensure that this is the
case. The preparation of the
main jack provides a good
example of this. The reservoir
is checked for dirt, fluid flow is
verified, and anti-seize
compound is spread on the
threads of the handle.
The same is true when
reviewing your setup: examine
the operation and determine if
you can establish some
equipment conditions in
advance that will reduce the
execution time. Some
examples include:
32
Eliminate unnecessary
walking, bending, lifting,
reaching, or sitting. Bring
needed items to the point of
use and within reach when
possible.
Reduce Motions
During the race, the pit crew
must be prepared to quickly
change tires. The number of
tire changers and air guns
allowed are regulated, so the
motions of each pit crew
member has to be reduced
and optimized.
Rethink Methods of
Fastening
Any fastening that must be
done during a pit stop can
consume precious seconds.
To reduce this time, all lug
nuts are inspected in advance.
The inspected lug nuts are
then glued onto the face of the
Since we all have the tool we need we do not have
to wait for one to be available and we do not waste
time looking through those other sizes.
Introduction
Organize the Setup Reduction Effort
Capture the Current Setup
Separate Preparation Activities from Execution Activities
Reduce Setup Execution Time
Implement the Revised Setup
Setup Reduction
33
Consider
Mechanization
When we watch a race, we
expect to see the pit crew
using an air gun to tighten lug
nuts on the wheels. But it was
not always that way - tire irons
used to be the tool of choice.
By mechanizing the tool, the
time required to tighten those
lug nuts has been substantially
reduced.
34
Eliminate Adjustments
When a crew member picks up
the jack, that tool must be
ready to use, with no
adjustments required. This
readiness is accomplished by
making adjustments before the
race begins. The jacks lifting
plate is preset for the race day
ride height. This height can be
affected by the banking of the
track, the tires used, or even
the weight of the driver. All of
these conditions are
considered and the adjustment
is made in advance.
Take a look at the adjustments
made during your setup
process. Could these
adjustments be eliminated by
the use of predetermined
measurements? Adjustments
or settings such as centering,
dimensioning, temperature,
pressure, and calibrations
should be reviewed and
established in advance when
possible. Use visual cues to
clearly designate acceptable
parameters on dials and
scales.
Introduction
Organize the Setup Reduction Effort
Capture the Current Setup
Separate Preparation Activities from Execution Activities
Reduce Setup Execution Time
Implement the Revised Setup
Some considerations:
Establish centering and
height standards for die
presses.
Standardize all
attachment devices so
that work can be done
quickly and easily.
In a retail environment,
establish set locations
and visual cues for
positioning items
displayed in a case.
Automate
Automation and technology
surround us and have become
commonplace. We expect to
see smart phones, personal
computers, scanners, and
even robots in our stores,
warehouses, and factories. But
how can these advances be
used to help reduce setup
execution time?
Setup Reduction
35
Since redesigning the product line, we need to make fewer different parts.
36
Introduction
Organize the Setup Reduction Effort
Capture the Current Setup
Separate Preparation Activities from Execution Activities
Reduce Setup Execution Time
Implement the Revised Setup
Insights
Ideally the goal is to
Setup Reduction
37
Summary
Analyze the setup execution activities and determine ways to perform
the work in less time. Investigate how reductions can be made with
the following strategies:
Dividing the work
Preparing operating conditions in advance
Reducing motions
Rethinking adjustments and methods of fastening
Mechanization or Automation
Redesigning the product or the process
Once you have reduced the execution time that is required for a
setup, you are ready to take action to reap the benefits. The next
chapter, Implement the Revised Setup, reviews the steps in making
the new setup a reality.
38
Introduction
Organize the Setup Reduction Effort
Capture the Current Setup
Separate Preparation Activities from Execution Activities
Reduce Setup Execution Time
Implement the Revised Setup
Implement the
Revised Setup
Setup Reduction
39
Strategies
To Implement the Revised
Setup:
1. Document the revised setup.
2. Train associates on the revised setup.
3. Conduct trials on the revised setup.
4. Go live.
5. Measure success.
7. Celebrate success.
6. Communicate results.
Benefits
Checklists
Create checklists to
supplement procedures.
Include all of the required
materials, tools, and activities.
Make checklists easy to
understand by using pictures
and graphics where possible.
40
Introduction
Organize the Setup Reduction Effort
Capture the Current Setup
Separate Preparation Activities from Execution Activities
Reduce Setup Execution Time
Implement the Revised Setup
Train Associates
A well-trained team is
necessary for success.
Conduct training for everyone
affected by the new process.
This could include setup
workers, operators,
maintenance employees,
supervisors, and process
engineers.
Conduct Trials
Depending on the complexity
and critical nature of the setup,
you may want to test the new
setup procedures prior to full,
live implementation. During
these trial runs, each
procedure can be carefully
reviewed and minor
adjustments made if
necessary.
Job Aids
Dont expect everyone to
remember everything
presented during the training
session. Provide job aids that
act as reminders or
incorporate mistake-prevention
at key points in the process.
John, take over for Dave so that he can go to training
now.
Opportunity to practice
Performance review and
feedback
Setup Reduction
41
Go Live
Once the setup team is ready,
the new procedures should be
launched. During this first run,
the setup reduction team
members should be present to
provide support and to solve
any problems that may occur.
Issues that are discovered
during the run should be
documented for consideration
by the team. If the team
revises the procedures they
must ensure that training
documents are updated as
well.
Once the revised setup is
finalized, the new expectations
for time and productivity
should be put in place. Be sure
to inform production planners
and schedulers of the new
procedures so that they can
adjust for how the new setup
may impact their plans.
42
Celebrate Success
Once you have proven the
success of the new setup
procedure, plan an appropriate
celebration or a recognition
ceremony. Set a date to
formally celebrate the results
of the improvement and its
impact on the operation. Invite
members of upper
management to attend. Their
attendance will show their
commitment and emphasize
how important setup reduction
is to your organization.
Introduction
Organize the Setup Reduction Effort
Capture the Current Setup
Separate Preparation Activities from Execution Activities
Reduce Setup Execution Time
Implement the Revised Setup
Continuous
Improvement
A setup reduction program is
not a one-time thing. Even
after new procedures have
been implemented, there must
be methods in place that allow
for continuous improvement.
The people performing
the setup should have a
way to communicate
improvement ideas. This
communication method
should be effective and
improvement ideas should
not just end up in a file.
Insights
To successfully develop Tracking improvements
and implement a setup
reduction program, all
employees must be
involved and committed
to the process.
Supervisors should be
provided with additional
training to emphasize
the importance and
philosophy of setup
reduction.
Continue to measure
progress. This
measurement should
become part of a weekly
or monthly report and be
posted for all to see.
The measurements
should be monitored so
that any variations can be
investigated.
The Operations
Engineering department
should review the
successful setup
reductions and determine
if these same procedures
could be used elsewhere
in the company.
Setup Reduction
43
Summary
Implementation of the revised setup is the exciting moment when you
will begin to realize the benefits of the work you have invested in the
setup reduction process. Be prepared to allocate time to the
implementation and follow the implementation steps to ensure
success:
Document the revised setup
Train associates on the revised setup
Conduct trials on the revised setup
Go live
Measure success
Communicate results
Celebrate success
For a setup reduction effort to have a lasting impact, there must be a
drive for continuous improvement. The methods you employ to
implement a setup reduction process can set the stage for this
continuous effort.
44
Conclusion
We have all heard the saying 'time is money.' This is especially true in the area of setups.
Setup activities are non-value added activities that use resources and impact response time.
Every industry has setups - from the service industry to distributors to manufacturers.
Identifying and reducing the amount of time spent on these activities provides a competitive
advantage.
While everyone knows that setup reduction is necessary, many companies just dont know
where to start. There are some specific strategies and tactics that you can employ to get your
setup reduction process going. Start by organizing for setup reduction:
Draft a game plan.
Identify why the setup reduction effort is necessary.
Establish a team.
Identify and provide resources.
Once the effort is underway, then you can continue the process of setup reduction:
Separate setup preparation activities from setup execution activities.
Reduce setup execution time.
Implement the revised setup.
Obviously, this does not happen in a day. As you begin the process of setup reduction, it helps
to remember why you are doing this and what benefits you hope to achieve. Reducing the
amount of time spent on setup can result in:
Quicker response to customer demands.
Flexibility in scheduling, production, and delivery.
Reduced inventory.
Better productivity.
Improvements in quality.
Beating the competition.
Setup Reduction
45
Setup Reduction
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