Setup Reduction refers to a decrease in the changeover time. The setup reduction attempts to reduce every possible second from the changeover or setup time. Because the changeover or setup is not transforming any materials or services that a customer has agreed to pay for, both setup and changeover can be considered a form of waste/muda. In most cases a setup reduction can reduce the setup time by 50% or more.
The ©REDUCE methodology by Lean Strategies International LLC is a systematic way of reducing both setup and changeover times. For more information on the ©Reduce Methodology visit our recent blog post on Listen to the Gemba, Changing things around.