In today’s fast-paced manufacturing environment, efficiency isn’t just a competitive advantage—it’s a necessity. At KORN CONSULT GROUP, we recently partnered with a client to transform their setup processes using the SMED (Single-Minute Exchange of Die) methodology. The results? Significant cost savings, streamlined workflows, and a return on investment in under 12 months.
Our Approach: More Than Just Time Tracking
Every great solution starts with insight. We began with an on-site setup analysis, observing real-time operations to measure setup durations and distinguish between internal and external activities. Internal activities are those that can only be performed when the machine is stopped, while external tasks can be executed while the machine is still running.
Next, we hosted collaborative analysis workshops involving cross-functional teams. By bringing together production, maintenance, and operations experts, we gained a 360-degree view of the setup process. This helped us uncover hidden inefficiencies and bottlenecks that might otherwise go unnoticed.
With these insights, we worked on clearly defining tasks related to preparation, execution, and follow-up. Our focus? Identifying and shifting as many tasks as possible from internal (machine downtime) to external (machine running) to maximize productivity.
The Impact: 3 Concepts to Transform Setup Times
Our deep-dive analysis yielded three tailored concepts designed to reduce setup times and streamline process flows. These concepts aimed to eliminate unnecessary steps, simplify task execution, and promote better coordination among teams.
The Results: Tangible Value Delivered
- Cost Savings: The optimized setup processes are estimated to save the client €70,000 annually.
- Quick ROI: With a projected return on investment of under 12 months, the solution delivers fast and sustainable value.
Ready to Optimize Your Operations?
At KORN CONSULT GROUP, we don’t just offer solutions—we deliver measurable results. If your organization is ready to reduce setup times, cut costs, and boost efficiency, our team of experts is here to help.
Contact us today to schedule a consultation and discover how SMED can transform your operations.
