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Onsite SMED Kaizen Event

Setup Reduction (SMED) Kaizen Event

Two Days to Faster Setups

Kaizen symbolThis intensive two-day Setup-Reduction Kaizen Event (blitz) generates order-of-magnitude improvements in setup time and setup cost. The immediacy and urgency of this session changes paradigms, generates enthusiasm and brings rapid, low-cost solutions. 

Setup Reduction or SMED is the key to small batches, fast response, quality, and Kanban production control in many situations. 

Program Summary

Format Onsite Workshop Who Should Attend?
Time 2-Day Setup Operators
Production Operators
Cost $5500 (Includes Travel)
Participants 5-16
Next Step Call us at 816-931-1414

36 Hours To Faster Setups

Videotape & Prepare-Strategos helps identify a setup and client videotapes it. Preparations are made and resources such as Maintenance, Engineering and Tool Room are reserved. Team members are assigned.

Train- Four hours of training prepares the teams with tools and techniques for analysis. Analyze- Teams analyze videotapes and plan improvements.

5-S- Teams execute 5-S techniques to clean, paint, arrange and organize the equipment and the area.

Modify, Repair & Build- Repairs and changes to equipment and tooling are made. Fixtures, racks and carts are built. Maintenance and Tool Room personnel may work into the night. 

Practice- Teams practice setups & videotape improvements.

Standardize- Some team members practice; others document the setup. 

Follow-Up- Some improvements must be left for later. These are documented. Your Strategos advisor continues support via phone and email.

Participants Will Learn...

Program Outline

1. The Importance of Setup Reduction

Optimum Lot Sizing


2. The Four Phases

Organization, Maintenance & Housekeeping

Converting Internal Elements To External

Improving Elements

Eliminating Adjustments

3. Documenting Current Practice

Using Videotape

Process Charting

Multi-Task Charting

4. Improving The Setup

Specific Techniques for Various Industries


Analyzing The Tapes & Charts

5. Implementing Your Program

Establishing Metrics

Setting Priorities


Reinforcing Setup Loops

Several effects and behaviors push firms towards long setups and large batches.

Phases of Setup Reduction

Eliminating Adjustments

Videos of actual setups show how to eliminate adjustments and make setups both faster and more consistent.

Eight-color Printing Press

Changeover on Printing Press

Into Practice

This participant is practicing improvements on an eight-color printing press. The team reduced changeovers by 50%.

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The Strategos Guide To Value Stream and Process Mapping goes  beyond symbols and arrows. In over 163 pages it tells the reader not only how to do it but what to do with it.

Strategos Guide to Value Stream & Process Mapping

Lean Briefing is only sent to those who subscribe or those who download from the Strategos website.

Books & Videos

Guide to Cycle Counting

Warehouse Planning Guide

Human Side of Lean Video

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PUB FEB 2016