Verify that you have a valid set-up reduction project:

The initial machine (or process) for a set-up reduction project should have been identified by using one (or a combination) of the following techniques:

• MPX flow modeling.
• Process mapping.
• Spaghetti diagrams.
• Set-up metrics.
• Excessive queues.
• Excessive WIP and/or finished goods inventory.
• Factory tour.

The Supplier Development engineer should review this preliminary data and justify to himself that a need exists for a set-up reduction project.  A main reason for justifying a set-up reduction project is that added capacity is required to achieve production requirements.  Production is typically achieved by reducing lot sizes and set-up times.  Not all Supplier Development efforts will require a set-up reduction project.
 

Conduct a Rollout Meeting at the Supplier:

Communication is critical for a successful project.  The Supplier Development Engineer should conduct a rollout meeting at the supplier.  Everyone who touches the process should be invited to the meeting.  The Supplier Development Engineer will explain the proposed project, and how it will reduce overall manufacturing cycle time.  The concept of cost reduction and shared savings will also be explained to the attendees.  Videos should be used to point out previous successful Deere-Supplier cycle time reduction projects, the concept of “value added” versus “non-value added” operations, and the importance of teamwork to achieve optimum results.  The Supplier Development Engineer will emphasize that the supplier has good people and that the current set-up process may be inefficient.  The employees need to be assured that they will not be placed under the microscope.

SD Setup Reduction Presentation

Establish a charter:

It is in the best interest of the Supplier and the Supplier Development Engineer to draft a project charter prior to the initiation of the set-up reduction project.  The charter will be a useful tool to insure advance planning and to keep the project in focus.  The charter should include the following sections:

• Business case
• Situation and goal statement
• Mission and vision
• Project scope
• Schedule and deliverables
• Assignments and roles
• Responsibility of the champion

It is recommended that the Supplier Development Engineer should strive for a quick hit success by achieving a 50% reduction in set-up times for the current process on the first attempt.  This should be accomplished with existing machinery and minimal investment.  The quick hit success will set an example to request further Supplier Development projects at the supplier.

The Supplier Development Engineer must obtain the support of the supplier management to furnish resources to the project.  In return, the Supplier Development Engineer will furnish coaching and project management expertise.
 
 

Last Modified on: Friday, 24-Sept-99

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