How long did it take Shingo to achieve setup changes from 1.5 hours to 3 minutes?

Shingo's work in reducing setup times from 1.5 hours to an impressive 3 minutes is a remarkable achievement often associated with the principles of Lean manufacturing, particularly around the concept of Single-Minute Exchange of Die (SMED). The correct response indicates that this transformation required a period of 3 months.

Achieving such a significant reduction in setup time typically involves thorough analysis and application of various techniques, such as streamlining the setup process, minimizing the number of adjustments needed, and possibly reorganizing the workspace and tools used during setups. This process is not instantaneous and usually involves iterative testing and adjustments as the team learns and applies these new methods.

The timeline of 3 months suggests a realistic duration for the necessary training, experimentation, implementation, and subsequent refinements of the new setup procedures. It showcases the commitment required by the organization to fully embrace the changes involved in Lean practices. Organizations may underestimate the time needed to achieve profound efficiency gains, but 3 months is a practical timeframe for such transformative work within the manufacturing context.