Managing Setup Operations

Setup can be understood as configuration, adjustment or calibration. That is, setup is the operation of interrupting production to perform tool change, so that machines and industrial equipment are adjusted. It is through the setup process that change in the manufacture of one type of product to another is performed.

The method for setup was developed in the 1950s by Shigeo Shingo, then a consultant for Toyota. It is also called Single Minute Exchange of Die (SMED), in reference to the goal of reducing tool-change times to less than 10 minutes.

Setup time is the duration during which manufacturing is interrupted for machinery and equipment to be adjusted. It’s the time elapsed between manufacturing the last good part of a product A and the first good part of a product B, when a change in tools is needed. Changeover time is the time between the last good part of a production batch and the approved part of the next batch. Setup times vary, depending on the technology used, the equipment used, product variations, and the production planning performed by the industry.

Performing a setup operation involves four steps, illustrated in Figure 1.

Managing setup operations with reduced setup time results in a number of benefits for companies, including:

  • Possibility of small-batch manufacturing;
  • Reduced lead time;
  • Increased flexibility;
  • Reduced inventories of in-process and finished products;
  • Minimization of failures, reducing scrap and rework;
  • Reduced delivery times;
  • Increased productivity;
  • Reduced production costs;
  • Improved customer satisfaction and company image with the market.

What about the provision of services? When it comes to providing services, in a hospital for example, what would a setup operation be?

Stay tuned to MANAGEMENT TIPS!

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