Excessive Process Setup Time

An important factor in meeting customer service levels is reduction of the time required to set up process operations. This is because long set up times negatively impact lead time for deliveries. Unrfortunately, many manufacturers, rather than dealing directly with the setup issues, will increase production batch sizes and inventory levels instead. The result is a costly increase in work in process inventory levels, manufacturing lead times and a decrease the flexibility required to deal effectively with a large number of orders. More than ever, diversity is an element of competitiveness, therefore processes must be flexible.

Effective methods have been conceived to specifically correct these problems with a focus on team workshops to reduce setup times using SMED.