Strategies for Setup Reduction

Provided by: ToolingU

The single minute exchange of dies (SMED) method, which strives to reduce setups to under 10 minutes, is a core approach to setup reduction. SMED focuses on transitioning internal steps to external steps, which can be performed while machines are running. Additional SMED practices include using setup teams in parallel operations and prepping tools, paperwork, and materials. Standardization and special devices like one-turn and one-touch fasteners and intermediate jigs also help reduce setup times. Setup reduction is one of the many goals of lean manufacturing. Reducing setup times allows manufacturers to perform more setups for smaller, more-varied batches so that they can better respond to customer demands. After taking this class, users should be familiar with methods and understand the importance of setup reduction.

Course Objectives:

  • Define setup reduction
  • Distinguish between traditional and lean manufacturing procedures
  • Define the concept of single minute exchange of dies
  • Distinguish between internal and external setup steps
  • Describe steps involved in setup preparation
  • Describe parallel operation
  • Describe setup applications that incorporate standardization
  • Describe one-turn fasteners
  • Describe one-touch fasteners
  • Explain how intermediate jigs are used for setup reduction
  • Describe strategies for choosing a setup reduction target
  • Explain the importance of predictable setup times
  • Describe the purpose of scheduled changeovers
  • Describe the benefits of setup reduction.

Recommended Background

  • Recommended for Manufacturing personnel, including technicians, engineers, and managers

Course ID


Skill Focus

Smart Business



Employee Type

New Applicants,1st level Supervisors, Operations teams, Leadership

Method of Delivery


Estimated Effort

2.5 hrs



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