Reducing High Setup Time in Assembly Line: A Case Study of Automotive Manufacturing Company in Malaysia

Lean Manufacturing System has been identified as an approach for improving performance of the processes and products. High setup time can be classified as waste for the company. This study will focuses on how an automotive manufacturing company in Malaysia is able to improve their operations time by reducing setup time and at the same time improve their productivity level. The objectives of this research are to identify the factors that influence high setup time and to highlight the action that can be minimized to reduce the setup time. Observations and interviews were conducted to understand the whole assembly process.