Long setup times quietly erode productivity, limit flexibility, and increase cost, but most organizations underestimate just how much opportunity is hidden in their changeover process.
This one-day workshop introduces a practical, hands-on approach to Setup Reduction using the SMED (Single-Minute Exchange of Die) methodology, helping teams dramatically reduce downtime and improve overall equipment effectiveness.
Participants will learn how to systematically analyze setup and changeover activities, separate internal and external tasks, and identify waste within the current process. Through real-world manufacturing examples and guided exercises, attendees will gain experience breaking down setups step-by-step and redesigning them for speed, consistency, and repeatability.
The workshop emphasizes practical application over theory. Participants will work through structured tools to document current state setups, identify improvement opportunities, and develop actionable future-state changeover processes. The focus is on building a repeatable method that can be applied directly on the shop floor to reduce variability and improve responsiveness to customer demand.
By the end of the session, attendees will understand how to apply SMED principles to reduce setup times, improve machine availability, and support lean flow. They will leave with a clear framework for leading setup reduction efforts and engaging operators, technicians, and engineers in sustainable improvement activities.
Course Highlights Include
After completing the MRC Setup Reduction for Manufacturing: A Practical SMED Approach, participants will:
- Apply SMED principles to systematically reduce setup and changeover times
- Learn how to separate internal vs. external setup activities to eliminate wasted machine downtime
- Identify and remove common forms of waste within setup processes
- Improve equipment availability and throughput without additional capital investment
- Develop a repeatable setup reduction framework that can be used across multiple machines or lines
- Strengthen cross-functional collaboration between production, maintenance, and engineering teams
Who Should Attend
- Manufacturing / Plant Managers
- Production Supervisors and Team Leads
- Process Engineers / Manufacturing Engineers
- Continuous Improvement (CI) / Lean Practitioners
- Maintenance Supervisors and Technicians
- Equipment Operators involved in changeovers
- Quality Engineers supporting process stability
- Operations Leaders focused on flow and capacity