Most manufacturing operations require periodic setups for product changes, process-control verifications or engineering evaluations. Setups performed in-line-on the tool in lieu of running product take away from production time and may be classified as waste. This paper focuses that, setup procedures should be analyzed to see if they can be done in parallel, off line, to allow production to continue. Alternatively, process checks might be accomplished with product parts instead of monitors, eliminating what is effectively downtime (waste) for a tool or sector. In this paper data was also calculated and collected after implementing of Set up Reduction Single Minute Exchange of Dies (SMED) technique. By implementing Set up Reduction (SMED), waste time is reduced from 113.75 h in June 2008 to 59.75 h in May 2009 with 585.00 h available time for machining. Productivity of machine also increases from 19 platens in June 2008 to 44 platens in May 2009.
Key words: Set up reduction, single minute exchange of dies (SMED), productivity, world class manufacturing, down time.