What's the best way to reduce setup times and improve efficiency on a CNC machine?

The best way to reduce setup times and improve efficiency on a CNC machine is to implement SMED (Single-Minute Exchange of Die) principles by moving as many setup tasks offline as possible before the machine stops running.

Key Strategies for Setup Reduction

• Offline Preset and Assembly : Build tool assemblies, measure offsets, and prepare raw materials and fixtures on a bench or tool cart while the machine is still running a previous job.
• Standardized Workholding : Use zero-point clamping systems, modular vises, or quick-change sub-plates so operators can swap fixtures in seconds instead of aligning parts manually with an indicator.
• Preset Datum and Tooling : Utilize a fixed reference datum on the machine table and pre-measured tool presets to eliminate manual touch-offs and guesswork.
• Kitting Tools and Programs : Create a dedicated kit for each job containing the exact program, inserts, bolts, wrenches, and setup sheets in one organized cart before starting.

Key Strategies for In-Cycle Efficiency

If you want, tell me:

• What type of CNC machine are you running (mill, lathe, router)?
• Are you doing high-mix low-volume or high-volume production?

I can give you more specific tips for your workflow.

The best overall approach is to treat CNC setup reduction as a SMED (Single-Minute Exchange of Die) project: measure the current changeover, move as much work as possible off the machine, then standardize and simplify what remains. This often produces bigger gains than simply asking operators to “work faster.”

Highest-impact improvements

1. Separate setup into “internal” and “external” work

• Internal = must happen with the machine stopped.
• External = can happen while the previous job is still running.
• Move tooling preparation, fixture assembly, material staging, program verification, and paperwork outside the machine-stop window.

2. Preset tools offline

• Measure tool lengths/diameters at a tool presetter rather than touching off every tool at the machine.
• Keep tools assembled in holders and ready to load.
• Maintain standardized tool numbers and offset data.

3. Standardize your workholding

• Use modular fixtures, repeatable locating pins, quick-change vises, or zero-point clamping where justified.
• The goal is to eliminate repeated indicating, squaring, and adjustment.
• Keep common fixtures at standardized heights where possible.

4. Create a complete setup kit Before the machine stops, have everything ready:

• Fixtures and hardware
• Tools/inserts/holders
• Raw material
• Gauges
• Setup sheet
• Correct CNC program revision
• Required inspection equipment

This eliminates the classic “machine is waiting while someone looks for a wrench/tool/fixture” problem. User Solutions FactoryOS 5. Use visual, standardized setup sheets

A good setup sheet should show the fixture orientation, tool list, work offsets, critical dimensions, probing procedure, inspection requirements, and photos. That reduces dependence on individual operator memory and makes setups repeatable. FactoryOS CNC Consulting and Training 6. Optimize job sequencing

If production allows, run similar jobs together—same fixture, tooling package, material, or workholding. Fewer major changes means fewer setups without changing the CNC process itself. FactoryOS 7. Measure “last good part → first good part”

Don't just measure how long the operator spends changing fixtures. Measure the complete interval from the last acceptable part of Job A to the first acceptable part of Job B. Then record where every minute goes. This gives you a fact-based improvement target.

A practical improvement sequence

If I were optimizing a CNC cell, I'd do it in this order:

Measure → video the setup → classify every task → move external tasks offline → standardize tooling/fixtures → create setup kits → standardize the setup sheet → measure again.

Only after those inexpensive changes would I consider capital investments such as zero-point workholding, automatic probing, pallet changers, or automated tool management.

And don't optimize setup time at the expense of quality or safety: a 10-minute setup that produces three bad parts is worse than a 15-minute setup that produces a good part immediately. Research on SMED implementations also shows that setup reduction can improve ergonomics when the process is redesigned rather than simply sped up.

A good first target: take your current average setup time and try to eliminate 20–30% without buying anything. The biggest opportunities are usually staging, searching, tool presetting, fixture alignment, and waiting.

The biggest gains in CNC setup efficiency usually come from reducing the amount of time the machine is stopped, not from making the operator work faster. A good approach is to apply SMED (Single-Minute Exchange of Die) principles: separate tasks that require the machine to be idle from tasks that can be done while it is still running, then eliminate or simplify the remaining downtime.

1. Measure the current setup process

Start by timing a few real changeovers from last good part → first good part. Break the setup into steps:

• Finding tools
• Changing fixtures
• Loading programs
• Setting tool offsets
• Setting work offsets
• Proving out the first part
• Inspection and adjustments

You’ll often find that walking, searching, and waiting consume more time than the actual machining setup.

2. Prepare everything before the machine stops

Move as many tasks as possible offline:

• Pre-stage raw material
• Gather tooling and inserts
• Load toolholders
• Prepare fixtures
• Print setup sheets
• Verify CNC programs
• Preset tools

A setup cart or job kit dedicated to each upcoming job can eliminate repeated trips to the tool crib.

3. Standardize tooling and workholding

Reduce variation between jobs:

• Use the same tool numbering system across machines
• Keep common tools assembled in holders
• Use standardized vises, fixture plates, and locating points
• Create repeatable datum locations

Quick-change and modular fixturing systems can greatly reduce time spent indicating and aligning fixtures.

4. Preset tools away from the machine

Instead of measuring every tool at the spindle:

• Use an offline tool presetter when practical
• Store tool length/radius data with the tool
• Transfer offsets digitally if your setup supports it

This keeps spindle time focused on cutting rather than setup.

5. Improve fixture design

Look for ways to eliminate adjustments:

• Replace multiple bolts with quick clamps
• Add locating pins or repeatable stops
• Use zero-point or pallet systems for frequent jobs
• Keep fixture heights and datums consistent

The goal is to make a fixture locate correctly the first time rather than requiring repeated dialing-in.

6. Create better setup documentation

A good setup sheet should include:

• Fixture photo
• Part orientation
• Tool list with tool numbers
• Work offsets
• Critical dimensions
• Inspection points
• Notes from previous runs

Visual instructions reduce dependence on operator memory and make setups repeatable between shifts.

7. Use probing and automation where it pays off

Useful upgrades include:

• Tool setters
• Part probing
• Automated offset updates
• Program transfer systems
• Simulation/verification software

These reduce manual measurements and help catch errors before the machine cuts material.

8. Organize jobs to reduce changeovers

Scheduling can be as important as hardware:

• Group similar materials together
• Run jobs sharing the same fixtures or tools
• Sequence parts to minimize tool changes
• Maintain repeat-job standards

A practical improvement order

For many shops, the best return comes in this order:

1. Time and document setups
2. Create job carts/kits
3. Standardize setup sheets
4. Organize tooling and workspace (5S)
5. Add quick-change fixturing
6. Add presetting/probing/automation

Small process changes often deliver large improvements before investing in expensive equipment.

If you tell me the type of CNC (mill, lathe, 5-axis, Swiss, etc.), average batch size, and current setup time, I can suggest the highest-impact changes for that situation.

Reducing setup times (changeover times) and improving efficiency on a CNC machine typically relies on lean manufacturing principles like SMED (Single-Minute Exchange of Die) , standardization, and modern tooling strategies.

Here is a structured, step-by-step approach to dramatically cutting downtime and maximizing spindle uptime:

1. Implement SMED (Single-Minute Exchange of Die)
   • Separate internal setup (tasks done while the machine is stopped) from external setup (tasks done while the machine is running).
   • Convert internal tasks to external tasks wherever possible (e.g., pre-setting tools and staging raw materials while the machine is still cutting the previous job).
   • Streamline and standardize the remaining internal tasks using quick-release mechanisms instead of bolted connections.
2. Standardize Workholding and Use Zero-Point Systems
   • Invest in a zero-point clamping system (like pneumatic or mechanical quick-change subplates) so fixture swaps take seconds rather than hours.
   • Standardize fixture footprints, jaw types, and soft jaws across multiple machines to reduce the variety of hardware operators have to manage.
   • Pre-mount and align recurring fixtures on dedicated subplates off-line using a coordinate measuring machine (CMM) or optical presetter.
3. Adopt Preset Tooling and Tool Management
   • Use an offline tool presetter to measure tool length and diameter offsets before loading them into the machine, eliminating trial-and-cut cycles on the CNC.
   • Implement a sister-tooling strategy and automated tool life management so worn tools are swapped proactively rather than causing unexpected crashes or downtime.
   • Standardize toolholders and pull studs to ensure compatibility and quick loading into the automatic tool changer (ATC).
4. Digitize and Organize Setup Sheets
   • Move from paper setup sheets to digital, visual work instructions displayed on a touchscreen near the machine.
   • Include clear photographs of fixture locations, clamping torque specs, zero-point receiver positions, and loaded tool layouts.
   • Store proven G-code programs, offsets, and inspection reports in a centralized DNC/CAM network rather than local machine memory or USB drives.
5. Optimize NC Programs and Cutting Parameters
   • Utilize high-speed machining (HSM) and adaptive clearing toolpaths in your CAM software to maintain constant chip load and reduce air-cutting.
   • Eliminate unnecessary retract moves and optimize rapid traverse paths to shave seconds off every cycle.
   • Simulate programs completely using verification software (like Vericut or CAM-integrated simulation) to eliminate dry-run testing on the physical machine. 5S the Machine Enclosure and Tool Cart
   • Keep a dedicated, mobile setup cart containing everything an operator needs (calipers, edge finders, specific wrenches, pull-stud sockets, inserts, and clean rags).
   • Apply 5S principles (Sort, Set in order, Shine, Standardize, Sustain) to the area around the CNC so tools and materials are always in the exact same place.

If you want to tailor this, tell me:

• What type of CNC machine are you running (mill, lathe, 5-axis, Swiss)?
• Are you doing high-mix/low-volume work or high-volume production?

I can give you more specific recommendations for your setup.

The biggest gains usually come from treating setup as a process to optimize, not as unavoidable machine downtime. The best overall approach is SMED (Single-Minute Exchange of Die): measure the changeover, separate work that requires the machine to be stopped from work that can happen beforehand, then redesign the remaining steps. Studies of machining operations have reported setup reductions of roughly 40–57% using this approach.

Highest-impact improvements

1. Do as much as possible before the machine stops

• Stage raw material, fixtures, vises, jaws, gauges, inserts, and hand tools.
• Prepare and verify the next CNC program while the current job is running.
• Create a complete "job kit" so the operator isn't searching for anything during setup.
• Preset tool lengths/diameters offline rather than touching off every tool at the machine.

2. Speed up workholding

• Replace conventional bolted fixtures with quick-change fixtures where practical.
• Use locating pins/stops so fixtures don't have to be indicated from scratch.
• Consider zero-point/palletized workholding for frequently changed jobs.
• Standardize fixture interfaces across machines.

3. Standardize your setup

• Use a consistent setup sheet containing tool numbers, offsets, work coordinates, fixture information, inspection requirements, and program revision.
• Keep tools and setup hardware in predictable locations.
• Standardize fasteners, clamps, tool holders, and workholding wherever possible.
• Photograph/document proven setups.

4. Eliminate adjustment and trial-and-error

• Use fixed stops, locating features, preset offsets, and probing.
• Where appropriate, use probing to automatically establish work coordinates and verify critical features.
• Simulate programs and check tool/fixture clearances before running the job. Digital simulation can catch problems before they consume machine time.

5. Reduce operator walking and searching

• Put the setup cart immediately beside the machine.
• Keep frequently used tools at point of use.
• Organize the work area according to the sequence of the setup.
• A surprisingly large portion of setup waste can be motion, searching, and waiting rather than actual machining work.

6. Run setup activities in parallel

• If two people are involved, divide tasks instead of having one person wait for the other.
• Have one person prepare tooling while another changes workholding, when safe and practical.
• Prepare the next job while the current job is still cutting.

Measure before buying equipment

Record a few actual changeovers with a stopwatch or video. Break the time into categories such as:

Unload → clean → remove fixture → install fixture → indicate → load tools → tool offsets → load program → work offset → first-piece inspection → adjustments.

Then ask of every step: "Does the spindle actually have to be stopped for this?"

That question is the heart of SMED. Research from NIST also emphasizes identifying which setup bottlenecks produce the greatest improvement in overall production rate rather than simply reducing whichever setup step happens to be easiest.

A practical priority order

If I were improving a typical CNC job shop, I'd tackle it in this order:

1. Setup measurement → 2. Job kits/staging → 3. Standard setup sheets → 4. Offline tool presetting → 5. Quick-change/standardized workholding → 6. Probing/automatic verification → 7. Program simulation → 8. Automation/palletization.

Don't start with expensive automation. A well-organized setup process can produce substantial gains before spending much money; published machining case studies have achieved major reductions simply by reorganizing and standardizing the changeover process.

If you tell me what type of CNC you have (3-axis mill, 5-axis, lathe, router, etc.), typical setup time, and how many jobs you run per shift, I can identify the likely biggest time sinks and suggest a concrete setup-reduction strategy.

Reducing setup times and improving efficiency on a CNC machine comes down to embracing SMED (Single-Minute Exchange of Die) principles, standardizing processes, and optimizing your workflow off the machine so the spindle keeps running.

Here are the best strategies to slash downtime and boost productivity:

• Implement Presetting and Off-Line Tool Measurement : Use a dedicated tool presetter to measure tool lengths and diameters outside the CNC machine. Loading tool offset data directly into the control eliminates trial-and-error cutting, first-part scrap, and sitting idle while manually touching off tools.
• Standardize Workholding and Fixturing : Move away from custom, one-off clamping for every job. Invest in modular zero-point clamping systems, sub-plates, or quick-change vise jaws. This allows operators to swap entire fixture setups in seconds with repeatable precision.
• Organize with Kitted Tooling and Dedicated Carts : Create dedicated tool carts or shadow boards for specific jobs or families of parts. Keep all required inserts, wrenches, soft jaws, and holders together so operators aren't hunting across the shop floor for missing components during a changeover.
• Digitize Setup Sheets and NC Programs : Replace messy paper printouts and binder notes with digital setup sheets loaded right at the machine or via a shop network. Ensure photos of the fixture layout, torque specs, and exact zero-point locations are crystal clear.
• Adopt SMED Principles : Separate internal setup tasks (things that must be done while the machine is off, like physical bolting and cleaning) from external setup tasks (things that can be done while the machine is running, like staging raw material, pre-assembling tools, and pulling the next program).
• Streamline Chip and Coolant Management : Optimize chip evacuation during cuts to prevent bird-nesting or manual clearing stops. Use programmable coolant nozzles or high-pressure systems to keep the work zone clean and reduce manual post-operation wiping.

If you want to tailor this further, tell me:

• What type of CNC machines are you running (e.g., 3-axis mills, lathes, 5-axis)?
• What is your current average setup time and biggest bottleneck?

I can give you a step-by-step implementation plan for your specific shop.

The biggest gains in CNC efficiency usually come from reducing non-cutting time—especially setup, tool changes, probing, waiting, and operator searching—not from simply increasing cutting speed. A good approach is to combine lean setup methods with better tooling and process control.

1. Analyze and reduce setup steps (SMED approach)

Use SMED (Single-Minute Exchange of Die) principles:

• Record a few complete setups with a stopwatch or video.
• Separate tasks into:
  • Internal setup: must happen while the machine is stopped (fixture mounting, work offsets).
  • External setup: can happen while the machine is running (tool preparation, material staging, program review).
• Move as many external tasks as possible before the machine stops.
• Remove unnecessary steps and standardize the remaining ones.

Example:

• Before: Operator stops machine → searches for tools → finds fixture → loads program → touches off tools.
• After: Next job's fixture, tools, material, and program are ready before the previous job finishes.

2. Use quick-change fixturing

Reduce time spent indicating and aligning fixtures by using:

• Zero-point workholding systems
• Quick-change vises
• Modular fixture plates
• Standardized locating pins and stops

The goal is to make a fixture change repeatable instead of requiring a fresh setup every time.

3. Preset tools offline

Avoid using spindle time for tool measurement:

• Use an offline tool presetter when possible.
• Keep frequently used tools assembled and measured.
• Standardize tool holders and stick-out lengths.
• Maintain a digital tool library with offsets.

This lets the machine spend more time cutting rather than being used as a measuring station.

4. Create setup kits

For each job or part family, prepare:

• Fixture
• Raw material
• Cutting tools
• Work instructions
• Inspection gauges
• CNC program revision
• Setup sheet

A simple “job cart” or kitting system can eliminate many small delays.

5. Standardize your CNC processes

Create repeatable standards for:

• Tool numbering
• Fixture locations
• Work offsets
• Program naming
• Setup sheets
• Inspection procedures

The less an operator has to figure out, the faster and more consistent setups become.

6. Improve CAM and programming workflow

Efficiency improvements often come from programming:

• Use proven templates for common parts.
• Reduce unnecessary toolpaths and air cutting.
• Simulate programs before loading them.
• Maintain a library of proven feeds, speeds, and tooling strategies.

Simulation and offline verification can prevent long troubleshooting sessions at the machine.

7. Schedule jobs to minimize changeovers

Group work by:

• Same fixture
• Same material
• Same tooling
• Similar setups

Running five similar aluminum parts together is usually faster than switching between aluminum, steel, and exotic alloys repeatedly.

8. Track the right metrics

Measure:

• Setup time (last good part → first good part)
• Spindle utilization
• First-pass yield
• Tool life
• Scrap/rework
• Operator intervention time

Without measurements, shops often optimize the wrong bottleneck.

A practical improvement order

For most CNC shops, the best return comes in this sequence:

1. Measure current setup time
2. Stage tools/materials before the machine stops
3. Standardize setup sheets
4. Preset tools offline
5. Add quick-change fixturing
6. Optimize CAM and automation

Many shops can achieve major setup reductions through organization and process changes before buying new equipment.

If you tell me your machine type (VMC, HMC, CNC lathe, 5-axis, etc.), average setup time, and whether you run prototypes or production batches, I can suggest the highest-impact changes.

The best way to reduce setup times and improve efficiency on a CNC machine is to standardize workholding and implement offline tool presetting , which eliminates manual alignment, edge-finding, and touch-offs inside the machine. Shifting internal setup tasks to external preparation—such as staging component kits, building permanent standard tool libraries, and utilizing zero-point clamping systems—cuts non-cutting downtime down to a fraction.

Core Strategies for Setup Reduction

• Zero-Point Clamping Systems: Allows you to swap modular fixtures and vises in seconds with high-precision repeatability, removing the need to re-indicate or tram the table for each new job.
• Offline Tool Presetting: Measure and set tool length and diameter offsets away from the CNC machine, letting you upload data directly into the control panel rather than consuming spindle time on manual touch-offs.
• Standardized Tooling Libraries: Keep a core set of frequent cutting tools permanently loaded in the Automatic Tool Changer (ATC), programming future jobs around these permanent positions to limit loading and unloading friction.
• Process and Fixture Redesign: Consolidate multiple operations into a single setup or use self-centering vises to reduce part handling and multi-sided reclamping steps.
• Digital Setup Sheets and Kits: Organize raw materials, inserts, and instructions ahead of time on dedicated carts using cloud-based tracking or digital job travelers so operators avoid searching for components.

Cycle Time & Efficiency Optimizations

• Optimize Non-Cutting Motion: Trim excessive Z-retract safety heights and streamline rapid travel moves to prevent unnecessary pauses in the G-code.
• Adaptive Toolpaths: Use high-efficiency roughing and trochoidal milling strategies to maintain constant tool engagement and lower overall cutting stress.
• Proactive Tool Life Management: Track wear schedules and replace inserts before unexpected mid-run breakages cause scrap or catastrophic downtime.

If you tell me what type of parts you are running (high-mix/low-volume vs. long production runs) and your current workholding method , I can give you a more targeted recommendation for your shop.

Reducing setup times and improving efficiency on a CNC machine comes down to standardizing processes, keeping tools and data organized, and minimizing manual intervention . Implementing proven lean manufacturing and SMED (Single-Minute Exchange of Die) principles will help you get the most out of your machine.

• Adopt SMED Principles : Separate internal setup steps (things that can only be done while the machine is stopped, like swapping vises) from external setup steps (things done while the machine is running, like pre-setting tools or gathering programs). Shift as much as possible to external setup.
• Standardize Workholding : Use quick-change zero-point clamping systems (like pneumatic or mechanical pull-stud systems) or modular vise jaws. This eliminates tramming, aligning, and bolting down heavy fixtures from scratch every time you change jobs.
• Pre-Set Offsets Off-Machine : Invest in an offline tool presetter. Measuring tool lengths and diameters outside the machine on a dedicated optical or camera presetter saves valuable spindle time and eliminates manual trial-and-error touching off.
• Implement Tool Preset Standardization : Use standardized toolholders, retention knobs, and preset gauge lengths. If every tool is assembled identically into the holder before reaching the machine, the control parameters remain consistent and predictable.
• Organize Dedicated Tool and Fixture Carts : Create shadow boards or rolling carts dedicated to specific repeat jobs. Keep the exact wrenches, pull-stud sockets, inserts, torque wrenches, and software printouts together so operators never waste time searching the shop floor.
• Streamline Program and Data Management : Utilize a reliable DNC network or a centralized server so operators aren't walking back and forth with USB drives. Keep up-to-date, verified setup sheets (with photos of the fixture layout and tool loading) digitally accessible right at the machine terminal.
• Design Poka-Yoke (Error Proofing) : Use alignment pins, keyed locators, and distinct hardware configurations so fixtures and parts can only be loaded the correct way. This eliminates costly first-part scrap and second-guessing during setup.

If you'd like to narrow this down, tell me:

• What type of CNC machine are you running (mill, lathe, 5-axis, multi-spindle)?
• Are you doing high-mix/low-volume work or high-volume production?

I can give you a more targeted strategy for your shop floor.

The biggest gains usually come not from cutting faster, but from making the machine spend less time waiting between jobs. A good approach is to treat setup reduction as a SMED (Single-Minute Exchange of Die) project.

1. Measure the current setup first

Time the process from the last good part of Job A to the first good part of Job B. Break it into individual activities—fixture change, tool loading, touch-offs, program loading, inspection, walking/searching, etc. Videoing a changeover can make hidden delays obvious.

2. Move preparation off the machine

Anything that can be done while the CNC is cutting should be done beforehand:

• Pull and inspect all tools.
• Preset tool lengths/diameters offline.
• Stage raw material and finished-part containers.
• Prepare the fixture and jaws.
• Verify the correct program and revision.
• Have the setup sheet and inspection equipment ready.

The goal is: when the previous job finishes, everything needed for the next job is already at the machine.

3. Standardize workholding

This is often one of the highest-value improvements.

Consider:

• Standard vise/fixture locations.
• Fixture plates with dowel-pin locations.
• Quick-change jaws.
• Zero-point/palletized workholding for frequently changed jobs.
• Dedicated soft jaws or modular fixtures for repeat families.

Repeatable locating eliminates much of the indicating, squaring, and searching that otherwise happens during every setup.

4. Preset tooling

If operators currently touch off every tool at the machine, move that work offline whenever practical. A tool presetter lets you prepare complete tool assemblies while the machine is running, then enter the verified offset data during setup.

For high-mix shops, this can be particularly valuable because tool measurement becomes external setup time rather than machine downtime.

5. Create a repeatable setup sheet

For every repeat job, document the proven setup rather than making the operator rediscover it.

Include things such as:

• Part number/revision
• CNC program and revision
• Fixture/vise and jaw information
• Tool list
• Tool offsets
• Work offsets/datum location
• Material and stock dimensions
• Coolant requirements
• First-piece inspection requirements
• Photos/diagrams of the setup

A good setup sheet turns tribal knowledge into a repeatable process.

6. Organize the physical workspace

A surprisingly large percentage of setup time can be walking, looking, and waiting. Keep commonly used setup equipment at point-of-use:

Machine → setup cart → tooling → workholding → inspection

A job-specific kit on a cart can contain virtually everything needed for the changeover. This also makes it easier for another operator to take over the job.

7. Standardize the CNC programs

Use consistent conventions for:

• Tool numbers
• Work offsets
• Program headers
• Tool-change positions
• Probing routines
• Safe-start blocks
• Tool-life information

The less an operator has to interpret, the less opportunity there is for setup errors and delays.

8. Reduce first-piece time—not just mechanical setup

A 10-minute fixture change isn't much of a win if it takes another 30 minutes to get an acceptable first part.

Use probing, standardized datums, proven tool offsets, and documented first-piece inspection procedures where appropriate. The real metric should be:

Last good part → first good part

not merely "fixture swap time."

9. Attack the biggest bottleneck first

Don't buy expensive automation immediately. Rank your setup activities by total minutes consumed.

For example:

That gives you a clear target and tells you where an investment—such as a presetter or quick-change fixture—will actually pay off.

A practical priority order

I'd generally attack a CNC setup in this order:

1. Measure → 2. Stage/kitting → 3. Standardize → 4. Preset tools → 5. Improve workholding → 6. Improve probing/programs → 7. Automate where justified.

This approach can produce substantial reductions without immediately buying new machines or elaborate automation. A published machining case study, for example, reported setup reductions of 40% on a vertical mill and 57% on a horizontal mill using SMED principles.

If you tell me what kind of CNC you have (3-axis mill, 5-axis, lathe, mill-turn, etc.), typical setup time, and whether you're high-mix/low-volume or production, I can lay out a much more specific setup-reduction strategy.