Course Overview
Setup reduction (often known as Single Minute Exchange of Die or SMED) is one of the more mundane aspects of Lean Manufacturing and is often ignored. This leads to the creation of several vicious circles in the manufacturing system.

When we run large lots of each product, setups on that product are infrequent. Setups take skill, practice and coaching, much like golf. When operators perform setups infrequently, they do not learn them well.

This leads to the perception that setups are difficult and risky (you never know how long it will take or whether the product will be right). The perceptions of risk and difficulty encourage large lots and thus fewer setups, higher costs.

SMED is a method of systematic seeking for setup time reduction, according to quantified target.

Single Minute Means: necessary setup time is counted on a single

Setup reduction and fast, predictable setups enable Lean Manufacturing.
 ·Setup cost
 ·Allows small lot production
 ·Smoothes flow
 ·Improves KANBAN implementation
 ·Reduces throughput times
 ·Reduces inventory
 ·Easier production scheduling
 ·Smaller lot sizes