This is part 6 of our Lean Manufacturing Training Toolkit, which supports furniture manufacturers who want to introduce lean principles into their organisation or re-energise their current lean programmes.
As the tastes of the modern customer have become more diverse, companies have needed to reduce batch sizes. As batch sizes have reduced, the impact of set-ups on the ability to satisfy the customer has become more significant. It is no longer acceptable or good practice to produce ahead of a constantly changing demand. Companies must develop a strategy to reduce the impact of long set-up times.
The Lean Principle of ‘Set-up Reduction’ aims to minimise the time and resources needed to switch from one product or process to another and provide the following benefits:
- Increase machine availability (reduce non-productive time)
- More frequent set-ups and improved process flexibility in line with customer demand
- Smaller production runs, reduced inventory costs (less stock to transport, monitor and store)
- Shorter lead time, improved response to the customer
- Reduce inventory and less cash held in stock in the warehouse - improve cash flow - competitive advantage
This toolkit includes the following:
- Guidance for undertaking Set-up Reduction activity
- Set-up Reduction training agenda
- Set-up Reduction training presentation
- Set-up Reduction presentation slide notes
- Set-up Reduction templates
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