Manufacturing companies straggle to meet a fluctuating market demand and deal with issues of price, quality and Lead (cycle) times. A slow change over in redraw presses has been one of the main constraints for the production process in bellow manufacturing plant. When the demand of the factory's products is high, this becomes the bottleneck among all the operations. Several problems prevent this part of the process to be faster and leaner such as: lack of standardization during the machine setup, improper scheduling, irregular arrangement of tools, waste of time during machine handling, high number of internal activities and low number of external ones, etc. Lean tool was applied to reduce the time and make the production flow smooth. A case study was conducted in a manufacturing plant in Knoxville and results are presented. The result shows substantial improvement in the process.
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