Conducted by KORN CONSULT GROUP, this project focused on analyzing and optimizing setup processes through the SMED (Single-Minute Exchange of Die) methodology. The core aim was to minimize production interruptions caused by lengthy setup times.
The initiative began with a cross-departmental workshop, fostering collaboration across units. Through on-site observation, setup activities were documented and classified into internal (requiring machine stoppage) and external (performed while machines run) processes. This clear classification enabled the team to identify and shift tasks strategically, reducing internal setup time.
As a result, three solution concepts were developed. After evaluating the cost-to-benefit ratio of each, one was selected for implementation. The chosen concept is projected to save approximately €70,000 annually, with a return on investment expected in under 12 months.
The SMED workshop not only streamlined setup processes but also enhanced teamwork and engagement—demonstrating the effectiveness of structured process optimization in achieving measurable performance gains.
Ready to Unlock Hidden Efficiency in Your Production?
Discover how structured methodologies like SMED can deliver significant cost savings and performance improvements. Partner with KORN CONSULT GROUP to optimize your setup processes, minimize downtime, and boost team collaboration—just like we did for our latest client, saving them €70,000 annually.
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