Achieving Lean Changeover

Achieving Lean Changeover: Putting SMED to Work

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ISBN 9781466501744
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Features

  • Shares practical examples from a variety of industries
  • Examines lighter industries less frequently addressed, such as packaging, food processing, and printing, as well as heavier industries
  • Focuses on both mechanical and operation aspects, such as costs, waiting times, material movement, documentation, training, and product/component design
  • Provides information on why reducing changeover time is important financially and presents a structured methodology to identify and implement improvement opportunities
  • Devotes a chapter to organizing changeover improvements, keeping them on track and motivated, and developing and implementing a formal changeover reduction program

Summary

Defined as the total process of converting a line or process from one product to another, changeover will not only help your organization improve quality and flexibility, but it will save thousands and sometimes even tens of thousands of dollars per hour.

Achieving Lean Changeover: Putting SMED to Work is about the practical implementation of the single minute exchange of die (SMED) philosophy developed by Shigeo Shingo at Toyota. Although the book is principally about changeover of manufacturing, packaging, and assembly processes, the general concepts and examples are also applicable in lighter industries that require turnover of processes—including airlines, hospitals, operating rooms, and food service.

Filled with practical examples, the book shares proven methods that can help you convert changeover downtime to productive uptime. It explains why reducing changeover time is important financially and provides a structured methodology to help you identify and implement improvement opportunities.

The author addresses both the machinery issues with changeover/ SMED and the associated operational issues such as costs, waiting times, material movement, documentation, and product/component design. He also devotes a chapter to discussing, in detail, how to calculate the cost of changeover downtime, an area that remains a mystery to many.

Taking a holistic approach to changeover, the text includes a chapter devoted to organizing changeover improvements, keeping them on track, and developing and implementing a formal changeover reduction program. Presenting time-tested methods and practical examples from a variety of industries, it offers you the opportunity to reduce changeover time and cost and provide your organization with the flexibility needed to better satisfy your customers in three important dimensions: product variety, responsiveness, and price.

Table of Contents

Introduction
Definitions
     Changeover
     The 3 Ups
     Changeover Time
     Downtime
     Quality
Importance of Changeover
Pit Stops
History of Changeover
Tactic or Strategy?
The ESEE Concept

Changeover Costs
Knowing Your Costs Is Critical
WIIFM
Tangible Costs of Changeover
     Lost Production
     Lost Capacity
     Reducing Changeover Times Creates Additional Capacity
     Impact on Inventory
     Labor Costs
     Product and Material Losses
     Intangible Costs
     Response to the Customer
     Capacity Utilization
     Quality
     Stress on People, Machines, and Systems
     Reduced Innovation
Conclusion

Standard Operating Procedures
     Cleaning Is Inspecting
     Graphical SOPs
Writing the SOP
Electronic SOPs
Conclusion

Eliminate
Product Design
Documentation
Quality Clearance
Schedule Production Weak to Strong
Building Design
Separate Clean and Dirty
Don’t Clean Unused Equipment
Batch Versus Continuous Processing
Label Position
Cam
Ladders
Quick Connectors
Pucks
Servo Motors
Machine Covers
Eliminate Conveyor Rail Adjustment
Multiple Photoeyes
Kit Manufacturing
Preset Timing Adjustments
Movable Motor Mounts
Sprockets and Gears
Conclusion

Simplify
Smooth Surfaces for Cleaning
Washroom
     Drying
Conveyors
     Machine Cabinets
     Clean-in-Place
     Pigs
Tools
No Tools
     Hand Knobs and Levers
     Quick-Acting Knobs and Levers
     Spring-Lock Collar
     Pins
     Snaps
     Magnetic Locking
     Vacuum Mounting
     Tool-less Plunger Mount
     Quarter-Turn Fasteners
     Tool Changers
     Toggle Clamps
     Conical Cylinder Locks
     Interrupted Threads
     Slots and Keyholes
     C Washers
     One-Touch Guide Rail Adjustment
     Single-Point Adjustment (Double Lead Screw)
     Captive Washers
     Unitary Lane Spacers
     Asymmetric Parts
     Scissor Jacks
     Changepart Identification
Conclusion

Externalize
Material Handling
Changepart and Tool Handling
Standardized Components
Pre-heating
Duplicate Components
Clean-in-Place
Dual Rollstands
Testing
Conclusion

Execute
Speed
Positioning
     Scribe Marks
     Scales
Gauges
     Thickness Gauge
     Leaf Gauge
     Digital Indicators
     Micrometer Adjusters
Adjusting Stops and Jacking Screws
Use the Force
Conclusion

Develop and Implement a Program
Process or Project?
Forming the Team
     Starting the Team
Who Performs Changeovers
Getting to Work
Conclusion
Appendix

Author Bio(s)