Setup time

Setup (or changeover) is everything that happens between the last good part of one batch and the first good part of the next. In shops with small batches, setup can take more time than production itself, so it weighs directly on availability and price.

How it works

The best-known method to cut setup is SMED (single-minute exchange of die). The idea is to separate what can only be done with the machine stopped (internal setup) from what can be done while it runs (external setup), such as staging tools, presetting lengths and proving the program. Then fixturing and datums are standardized so the changeover becomes a short, repeatable sequence.

Practical example

A machining center took 75 minutes to switch parts. With tools preset off the machine, vises with fixed locating and a checklist, setup dropped to 28 minutes. With 3 changeovers a day, the machine gained more than 2 hours of production daily.

Common mistakes

• Looking for tools and shims with the machine stopped.
• Not measuring setup separately from production, hiding the loss inside a generic OEE.
• Quoting small batches without spreading setup over the part price.