Setup Reduction (Setup Improvement) Program – GRUPAS GELİŞİM
Setup is the process of switching a machine or piece of equipment from one product to another within a production process: the time elapsed from all the changeover work and adjustments performed after the last good product until the first sound product is obtained on the new one. In many plants these times are extremely variable; there is no common standard, employees use different work techniques and methods, and many activities that could be carried out while the machine is running are instead performed with the machine stopped. The GRUPAS Setup Reduction program eliminates these losses on the shop floor, with a data-driven, structured 6-step road map: selecting the setup type and setting targets, defining the current standard and training operators, establishing an abnormality & time recording system, eliminating abnormalities (with 5 whys and cause-effect analysis), improving the standard through micro-activity and ECRS analysis, and simplifying adjustment methods.
What the Program Brings to Your Company
- Potential to shorten setup times by at least 50%: 30% improvement through eliminating small problems and an easy-to-follow standard, 50% with simple arrangements
- Effective reduction of operator effort and elimination of experience-dependent variability
- Reduced machine downtime, increased capacity and OEE; more output with the same equipment
- Standardization: the best method defined on video, repeatable application and training for all operators
- Production flexibility with small batches, faster product changeovers, lower inventory and shorter lead times
- A permanent, irreversible improvement culture through systematic recording and follow-up of abnormalities
- Transparent measurement, target tracking and sustainable gains with a machine performance dashboard
Who Is It For?
Manufacturing companies producing series or highly varied products; those responsible for production, planning, maintenance and continuous improvement (Lean Manufacturing / SMED), production managers, shift supervisors and operator teams.
