Setup Reduction

During Value Stream analysis exercises, often our clients primary goal is to improve throughput. There are many potential causes that choke our processes reducing our agility in producing what our customers want, when they want it. High on the list is the ability to change swiftly from making one product to making another, referred to as setup time.   We demonstrate with clients a need to closely examine the details and follow a systematic methodology. A method we deploy that helps of keep track of aspects is an acronym FAST TRAC.
  • F – Foresight
  • A – Attachment
  • S – Settings
  • T- Trials
 
  • T- Training
  • R- Recording
  • A- Application
  • C- Continuous Improvement
  We find typical results in the range of 60% to 90% reductions in setup time. These results hold true in every industry and many types of processes in discrete applications as well as continuous operations.

Written by