Setup Reduction key to On-Time Delivery

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A Connecticut-based industrial manufacturer was having problems meeting customer demand on one of their premier products. Members of the New England Lean Consulting team reviewed their entire Value Stream to identify non-value added and wasteful activities. After review, it became apparent that much of the problem could be attributed to the setup of one particular machine. After leading a 3-day Setup Reduction kaizen, we delivered a setup time reduction from 3 hours to 35 minutes, an 83% reduction.