But now I realize that reducing setup time is actually the key to reducing bottlenecks, lowering costs, and improving the quality of your products. Setups are, from this perspective, the most critical element of the process.
—Bodek (1983, p. xiii)
Setup times are one of the six big losses that are included in calculating overall equipment effectiveness (OEE = availability rate × performance rate × quality rate). The availability rate consists of set-up and adjustment losses as well as breakdown losses. The set-up time is the downtime that occurs when equipment or a work position is adjusted or prepared to be able to produce a different kind of a product. The adjustment losses are those associated with defective ...
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