Strategies for Setup Reduction 250

This class covers different strategies for reducing setup times, including ideas for streamlining operations and tactics for pre-staging processes. Includes an Interactive Lab.

Class Details

Class Name:
Strategies for Setup Reduction 250
This class covers different strategies for reducing setup times, including ideas for streamlining operations and tactics for pre-staging processes. Includes an Interactive Lab.
Number of Lessons:
Additional Language:
Spanish, Chinese
Related 2.0 Class:
Strategies for Setup Reduction 251

Class Outline

  • Objectives
  • Setup Reduction
  • Traditional Manufacturing vs. Lean
  • Single Minute Exchange of Dies
  • Internal vs. External Setup Steps
  • Setup Preparation
  • Setup Teams
  • Standardization
  • Improving Threaded Fasteners
  • One-Touch Fasteners
  • Intermediate Jigs
  • Intermediate Jig Example
  • Timing Setups
  • Targeting Setups
  • Benefits of Setup Reduction
  • Scheduled Changeovers
  • Summary


  • Define setup reduction.
  • Describe the relationship between setup and production runs for traditional manufacturers.
  • Define the concept of single minute exchange of dies (SMED).
  • Distinguish between internal and external setup steps.
  • Describe steps involved in setup preparation.
  • Describe advantages of using setup teams.
  • Describe setup applications that incorporate standardization.
  • Describe applications for threaded fasteners that encourage quick changeovers.
  • Identify characteristics of one-touch fasteners.
  • Describe setups that incorporate intermediate jigs.
  • Identify the parts of a typical intermediate jig setup.
  • Explain the importance of predictable setup times.
  • Describe the criteria for choosing a setup reduction target.
  • Describe the benefits of setup reduction.
  • Describe the purpose of scheduled changeovers.


  • MSSC Manufacturing Processes and Production


Vocabulary Term Definition
changeover The process of switching a machine from making one type of part to another.
chuck A workholding device with moveable jaws that grip a revolving workpiece or cutting tool on machines such as the mill, lathe, or drill press.
collet A slitted device that holds a workpiece or cutting tool in place as it rotates. A collet has a hole through which the workpiece passes, and it is designed to hold specific dimensions.
datum A common reference point for machine tools, programs, and fixtures.
die An assembled device used for forming or stamping sheet metal.
economic order quantity The number of orders required to minimize the cost of producing parts and holding them in inventory. Economic order quantity (EOQ) is a concern for more traditional manufacturing companies.
external step A changeover action that can take place while the machine is still running.
Five S A targeted list of activities that promotes organization and efficiency within a workspace. The Five S terms are sifting, sorting, sweeping, standardizing, and sustaining.
functional clamp A device designed to hold two or more parts or components together and prevent them from moving.
intermediate jig An interchangeable component that standardizes the locating and support of workholding devices for various machines. Intermediate jigs fit into a sub-plate or main part that does not move.
internal step A changeover action that can take place only when the machine has stopped.
kaizen event A multi-day, hands-on event that targets a particular problem area within a company. Kaizen events result in dramatic changes carried out by a cross-functional team.
lathe A machine tool that holds a cylindrical workpiece at one or both ends and rotates it while various cutting tools remove material. Turning is a common operation performed on the lathe.
locking pin A type of one-touch, cylindrically shaped fastener with two balls that extend to hold components together.
one-touch fastener A non-threaded attachment that clamps and unclamps with one push of a finger or hand. One-touch fasteners often have internal springs.
one-turn fastener A threaded attachment that clamps and unclamps with one revolution of the threads.
parallel operation The use of two or more people to set up the same machine at the same time. Parallel operation helps reduce setup times at the machine.
scheduled changeover A machine setup that takes place according to a calendar instead of direct responses to customer demand. Scheduled changeovers help level and balance production.
setup The series of tasks necessary to prepare a product for processing. Setup includes preparing machines and collecting paperwork, tools, and materials.
setup preparation Any changeover tasks that can take place while the machine is still running, such as collecting tools and paperwork and preparing fixtures.
setup reduction A systematic method of eliminating manufacturing setup steps and streamlining those steps that remain.
setup reduction team A group of technical and non-technical personnel that studies machines and processes to find ways to reduce or eliminate changeover steps.
setup technician A shop worker who specializes in preparing machines to make parts.
single minute exchange of dies A theory of setup reduction that strives to reduce the time it takes to perform machine setups to under 10 minutes.
standardization A practice in which as many elements as possible are made the same. Manufacturers use standardized fasteners, tools, fixtures, and designs to streamline changeovers.
sub-plate A device that is mounted and located on a worktable or machine to provide precise positioning for multiple, standardized intermediate jigs.
total productive maintenance A manufacturing improvement method that increases production and reduces waste through continuous attention to the condition of machines and processes. TPM's main goal is to maximize equipment usefulness across its lifespan.