The workshop was comprised of engineers, tool room, and operations staff – including machine operators. Team members documented existing change-over methods. Multiple opportunities were found to dramatically improve capacity with little investment or lead-time.
+ Standard work would reduce elapsed time variation experienced set-up to set-up.
+ Set-up work was separated into external actions (machine running) and internal actions (machine not running).
+ The team shifted as much work as possible from internal to external content.
+ We reduced internal content by reducing wasted motion, poor sequence, poor layout and by customizing some basic tools.
+ Team involvement created buy-in, sustaining gains and encouraging a continuous improvement mindset and culture.
+ Set-up times were reduced by more than 60% within one week of the workshop.
+ Total manufacturing costs were reduced by 20% due to increased productivity.
+ No capital investment or increase in manufacturing expenses were required to achieve results.
+ The purchase of additional equipment was no longer necessary.