ABSTRACT
Organizations that produce product in equipment-based environments should have setup reduction as a cornerstone of their Lean journey. A good understanding of the concepts and tools is needed as many people confuse the definitions of setup reduction and quick changeover. This chapter creates a baseline for understanding the concepts can be prepared to train and implement effectively with the team. Setup is the act of performing tasks at the end of a production run to the start of another production run. External work is performed when the machine is running. Generally when it is producing product, the machine operator is gathering items for the next production run. Internal work is performed only when the machine is off. The changeover step is the most common activity during this downtime as fixtures and parts are removed and reinstalled when the equipment is not running.
