1st Edition

Achieving Lean Changeover Putting SMED to Work

By John R. Henry Copyright 2013
    205 Pages 121 B/W Illustrations
    by Productivity Press

    205 Pages
    by Productivity Press

    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.

    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

    Biography

    John R. Henry