Setup performance indicators: A tool to systematize and standardize the setup process diagnosis

Abstract

Manufacturing industry is currently under a strong competitive pressure, not only from the developed countries, but also from countries with significantly lower labour costs. New products and processes are and will be fostered by the emergence of new manufacturing technologies, stimulated by intense competition. As complement, new management and labor practices, organizational structures, and decision-making methods will emerge. It is necessary to develop strategies that are capable of building a strong competitive position in the global market and the journey starts on the shop floor—on the capability to supply the client needs. One of the most critical point of production process in manufacturing industry is the Setup process. When companies give low attention to the Setup process or don’t know that it’s possible to improve it, the overall time spent on it can be really significant. Consequently, a significant percentage of production time is consumed in nonadded value activities, time that could be used in actual production or to increase production flexibility. This paper is about the creation of a tool capable to diagnose the Setup process. This tool is based on a methodology that allows identification and monitor Setup’s key process indicators (KPI)—i.e., total time, longer operations, waiting times, transports, handling and cleaning times. It also allows the Setup process control by assessing the KPI of consecutive Setups.