Setup reduction

Setup reduction is the process of reducing the amount of time needed to change a process over from the last part of the previous product to the first good part of the next product. It is carried out in six basic steps, starting with measuring the total setup time in the current state and ending with standardizing the new procedure.

Source checked1/1 values · 2026-10-25Methodology

Specification

1 source

Kind	methodology

Study notes

The six basic steps are: measure the total setup time in the current state; identify the internal and external elements and calculate the individual times; convert as many of the internal elements to external as possible; reduce the time for the remaining internal elements; reduce the time for the external elements; standardize the new procedure.
Setup time is defined from the last part of the previous product to the first good part of the next product.
The document points to Changeover and Single Minute Exchange of Die as related terms but does not define them.