The Newsletter of Lean Manufacturing Strategy

Drop Down Menu






Related Seminar

Rapid Setup Blitz

Kaizen Blitz for the shop floor - principles and implementation in an intense 2-day event.




Upcoming Topic

"Does TQM & Lean Pay Off for Shareholders?"

This Quantitative Study Says Yes, But...




Copyright 2003 Strategos, Inc.

February 28, 2003                       www.strategosinc.com


Setup Reduction & SMED

My last message discussed lot sizing and small lot production. With small lots, Kanban functions better and conventional scheduling is easy and flexible. But, small lots require fast, inexpensive and predictable setups. If your people and equipment already do this, Rapid Setup is of little concern- otherwise, read on.

In many industries, such as printing, setup reduction is a hot topic but the discussion mostly involves expensive technology. Significant setup reduction rarely needs new technology.

We recently conducted setup reduction training for a printer of labels. Their team's analysis identified quick and easy changes that reduced setups ("Make Ready" in the printer's vernacular) by 60%-70%.

In most cases, manufacturers can cut their setup time in half without a lot of new equipment, tools and fixtures. Sometimes the improvement is even greater. For examples go to www.strategosinc.com/setup_reduction3.htm .

For more on how to cut setups see our series of articles starting at:



A Kaizen Blitz is an effective way to start setup reduction. These events are exciting and dramatic. They produce fast, spectacular results. There is more at:



Unfortunately, setup reduction is a more mundane aspect of Lean Manufacturing. It does not have much glamour. But it can be critical for the success of a Lean Manufacturing strategy. Don't ignore it!

All The Best-

Quarterman Lee

Please feel free to forward this Lean Briefing to colleagues or use it in your publication. We only ask that you do so in its entirety.

Lean Briefing Archive Issues

Drop Down Menu



©2011 Strategos, Inc.

You may forward Lean Briefing to colleagues or republish it. Please do so in its entirety.

Strategos, Inc. ■ 3916 Wyandotte ■ Kansas City MO 64111 ■ 816-931-1414 ■ www.strategosinc.comSend Email