Setup-Time-Reduction-A-Comprehensive-Playbook - Level 2

This playbook is a detailed, data-driven guide to achieving 50–90% setup time reduction using the SMED (Single Minute Exchange of Dies) methodology, delivering major gains in capacity, cost, lead time, quality, and inventory performance.

It defines setup time, explains its impact across industries, and classifies activities into internal (machine stopped) and external (machine running) operations. Examples from Toyota, Bosch, Foxconn, Johnson Controls, Siemens, Pfizer, and others show real-world improvements—such as cutting changeovers from hours to minutes, reducing inventory by 37%, improving OEE by 12%, and increasing first-pass yield to 99%+.

The methodology follows four key steps:

1. Document current process
2. Separate internal vs. external
3. Convert internal to external
4. Streamline remaining operations

It provides a seven-phase implementation plan from assessment and team formation to full deployment and continuous improvement, backed by case metrics such as:

• 60% setup time reduction (28.7 → 11.4 min)
• 25% capacity increase without new equipment
• 37.5% WIP inventory reduction ($478K savings)
• 35–60% shorter lead times

The guide also addresses common challenges like operator resistance, shift variance, and budget limits, offering proven countermeasures.

In short, it’s a complete operational excellence blueprint for transforming changeovers into a competitive advantage.