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Setup Results

Setup Reduction- Typical Results

Setup reduction (SMED) techniques apply across many industries and process technologies. The list below shows some examples.

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Kaizen Event

Kaizen Event (Blitz)

Strategos Setup Blitz

 

Industry Equipment Before After %
Assembly Adhesive Applicator 12:09:00 0:21:00 97%
Assembly Air Cleaner Assembly 2:00:00 0:00:00 100%
Brake Mfg Briquette Press 1:05:00 0:12:00 82%
Brake Mfg Drill Machine 0:35:00 0:05:00 86%
Brake Mfg Segment Drill 12:00:00 1:12:00 90%
Cosmetics Capper Machine 0:09:36 0:03:21 65%
Electronics PCB Inserion-ICs 0:13:30 0:05:56 56%
Electronics PCB Insertion-Axial 0:05:18 0:04:18 19%
Electronics PCB Insertion-Radial 0:54:12 0:05:06 91%
Foundry Molding Machine 0:10:00 0:06:12 38%
Metal Cutting Casting Drill 1:00:00 0:09:00 85%
Metal Cutting CNC MILLING 2:00:00 0:00:00 100%
Metal Cutting FADAL HMC 1:45:00 0:15:20 85%
Metal Fab 40 Ton Press 0:48:00 0:04:00 92%
Metal Fab 750 Ton Hyd Press 2:10:00 0:42:00 68%
Metal Fab 800 Ton Press 6:00:00 0:10:00 97%
Metal Fab Aluminum Extruder 1:09:00 0:02:12 97%
Metal Fab Brake Press 0:37:00 0:04:00 89%
Metal Fab Draw Press 1:30:00 1:00:00 33%
Metal Fab Edge Trim Press 0:24:00 0:04:00 83%
Metal Fab Pilot Change-Muffler Press 0:07:00 0:00:15 96%
Packaging Flex Packaging Line 3:00:00 0:10:00 94%
Paper Sheeting 0:03:00 0:00:36 80%
Pharmaceutical Centrifuge 0:12:00 0:02:12 82%
Plastics 250 Ton Injection Molder 1:06:00 0:09:12 86%
Plastics Injection Molder 2:30:00 0:06:00 96%
Plastics Injection Molder 2:00:00 0:03:00 98%
Printing Kidder 6-Color Web Press 4:20:00 1:10:00 73%
Printing Press Make Ready 9:30:00 4:20:00 54%
Wood Router 0:09:00 0:01:18 86%

Note: Many of these examples were taken from our own clients' experience. Others are documented in the literature on Lean Manufacturing.

More...

Part 1- Why Setup Reduction

Part 2- How To Reduce Setup Time

Part 3- Typical Results of Setup Reduction

Strategos Setup Reduction Kaizen Event

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