Setup Reduction

Reduce Downtime with Quick Changeovers

The more you can reduce the amount of downtime between the last good piece off your current run to the first good piece off your next run, the more productive your operation can be.

Reducing set up times and accomplishing quick changeovers means your company achieves benefits including:

  • Shorter lead time
  • Less material waste
  • Fewer defects
  • Less inventory needed
  • Lower space requirements
  • Higher productivity
  • Greater production flexibility

How to Achieve Faster Changeovers

The first step in improving any process is to thoroughly understand its current state. A team-based approach to documenting the current changeover is the best place to start analyzing the changeover.

Following basic Single Minute Exchange of Die (SMED) principles helps to identify ways to reduce or eliminate setup times. Improvements can then be implemented and their results monitored. Once proven effective, the improved changeover techniques can then be standardized.

Leverage our Expertise

Our Lean consultants have extensive expertise in setup reduction techniques that yield well-documented results. We can help your company implement a proven methodology for collecting the right data and analyzing the important phases of your setup reduction processes.

Perhaps most importantly, this experienced outside perspective is combined with expert group facilitation skills. Working as a team, we can help your staff explore all possible avenues of improvement, stretching your thinking and often enabling you to accomplish even more than initially anticipated in reducing setup time targets.



CONNSTEP solved a huge problem for us and helped us bring our delivery rate to 100%. As a direct result of that, we have been awarded with an increase in business which, ultimately, will also benefit (our supplier) Har-Conn.”

CT manufacturer Pegaasus

Chris DePentima

CEO, Pegasus Manufacturing Inc.

“I see great value in the new experiences and perspectives CONNSTEP brings to our business, at reasonable prices. They’re not like consultants, they’re like partners in the business – willing to roll up their sleeves and help.”

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Mark Burzynski

President, Arthur G Russell Co

“CONNSTEP has proved to be a tremendous resource for ESI. CONNSTEP has helped us to adapt to today’s marketplace and remain a quality minded, competitive global player. Our ISO/TS16949 implementation process was efficient and rewarding. I look forward to our future projects with CONNSTEP.”

esi CT manufacturer

Ron Delfini

President, Engineering Specialties Inc.

“CONNSTEP worked with FuelCell Energy to educate and facilitate Lean initiatives and to help meet our needs to establish an overall production improvement plan. This plan has been utilized over a period of time as a ‘guiding light’ to spur numerous improvements that dramatically reduced our product cost.”

Tom Lucas

Manager, Fuel Cell Energy

“CONNSTEP is a valuable partner to Hologic, providing the expertise and ‘outside eyes’ everyone needs to keep their continuous improvement on track. We are now well-positioned on a dynamic growth path and look forward to a long-term relationship with CONNSTEP.”

Greg Safarik

VP Manufacturing Operations, Hologic

“Our experience working with CONNSTEP has brought us benefits we never expected. It’s a great team to work with!”

Bruce Wheeler

VP of Operations, Metal Finishing Technologies Inc.

“The goals of the team were to reduce manufacturing lead-time, reduce floor space utilized, and increase worker productivity. All the goals were met. CONNSTEP helped us to better compete.”

Tornik CT manufacturer

Dan Rubbo

General Manager, Tornik LLC

“The Business Growth Program is working well for us. We enhanced our website following the meetings to improve our SEO and become more visible to search engines. The segment on negotiating …  promoted changes in our thinking and improved how we interact with customers. The mentoring between sessions was helpful in boosting our progress.”

CT manufacturer Colonial Spring

Bill Lathrop

President, Colonial Spring Co.

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