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“Pitstop!” ™ Radical Set-up Time Reduction Process

Over the years, "Pitstop!" TM has saved thousands of hours of wasted time in many environments, including manufacturing, service industries, and health care. It was developed by Mr. Morman based on his experience with set-up reduction with printing giant, R. R. Donnelley where he coordinated the efforts of over 1,000 employees in 83 teams. Within two years, set-up time was reduced between 24% and 83% across over 60 machines and work cells. Although wage costs were cut over $1,000,000 per year, many areas experienced materials savings that were twice that of labor savings. The capacity gained by these workers is valued at several million dollars.  

Mr. Morman has also presented to groups such as Microsoft Corporation and the National Quick Changeover Conference.

What is “Pitstop?”

"Pitstop!" is a low cost / no cost methodology based on the Japanese "SMED" or Single Minute Exchange of Die system of set-up time reduction. It is the heart of the Toyota Production System.

"Pitstop!" seminars train crew members to cut set-up time by up to 80% or more, routinely, and in a short time frame.

What are the Benefits?

• Cuts labor costs.

• Slashes set-up waste.

• Reduces product variation.

• Creates capacity for additional work and higher sales volumes.

• Eliminates or defers capital expenditures to expand capacity.

• Improves scheduling versatility and on time deliveries.

• Builds team work and ownership among employees.

Because of its structured approach, and the short time needed to realize significant gains, "Pitstop!" is an ideal way to ensure the success of newly formed teams. Employees presently working under a team philosophy will also readily embrace the techniques and apply them quickly and effectively.

"Pitstop!" can be successfully applied to any machine or process, in any industry. Because "Pitstop!" teaches people to work smarter, not harder, the savings last year after year.

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