Product Flow (Set-up Reduction)

Type: Class lectures, practical exercises
Number of sessions: 10 sessions
Length of sessions: 4 hours
Total hours: 40 hours - OR this class can be conducted as a focused one-week Kaizen event. With full implementation completed by the end of five days!

Target audience:

The course is designed for employees from all organizations, profit or non-profit, public or private, service or manufacturing. The skills learned apply to set-up operators, mechanics and maintenance technicians, business owners, company executives, local, state and federal officials, health care professionals, financial professionals, middle managers, administrative personnel, and employees of manufacturing and service organizations. These skills have also been successfully used in various office environments to greatly reduce procedures.

Summary of content:

• Understanding the four cardinal time wasters in any set-up and its importance to daily workflow and productivity.
• Process inputs and outputs, differentiating internal and external work
• Virtual Factory Tours of other successful set-up reductions
• Video: The Winner’s Circle correlates a race car driving pit crew to your set-up crew.
• Target Area review. Verify existing set-up times. Dance Charts, Spaghetti Diagrams of various flows: people, information, materials.
• Video target area to analyze the data and timing to identify and eliminate waste. Data collection methods and establishing set-up reduction target goals.
• Red Tagging & Yellow tagging and implementation including: painting lines, establishing staging areas, inbound/outbound, shadow boards, cleaning stations, and other basic visual controls.
• Establishing short-term and long-term disposition areas.
• First round of improvements.
• Analyzing the “new current state” and implementing second round of set-up reduction improvements.

Objectives and benefits:

The objectives are for participants to significantly reduce “down time” any part of the organization and establish new standards which lead to a reduction of internal costs. Benefits include a reduction of internal costs and increase in competitive advantages, market share, and profits and achievement of long-term business goals and self-auditing. Benefits also include an increase in both employee and customer satisfaction.