John R. Henry
Published December 8, 2012
Reference - 205 Pages - 121 B/W Illustrations
ISBN 9781466501744 - CAT# K14403
Published July 27, 2017
ISBN 9781138409460 - CAT# K36187
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For Librarians Available on Taylor & Francis eBooks >>
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.
The 3 Ups
Importance of Changeover
History of Changeover
Tactic or Strategy?
The ESEE Concept
Knowing Your Costs Is Critical
Tangible Costs of Changeover
Reducing Changeover Times Creates Additional Capacity
Impact on Inventory
Product and Material Losses
Response to the Customer
Stress on People, Machines, and Systems
Standard Operating Procedures
Cleaning Is Inspecting
Writing the SOP
Schedule Production Weak to Strong
Separate Clean and Dirty
Don’t Clean Unused Equipment
Batch Versus Continuous Processing
Eliminate Conveyor Rail Adjustment
Preset Timing Adjustments
Movable Motor Mounts
Sprockets and Gears
Smooth Surfaces for Cleaning
Hand Knobs and Levers
Quick-Acting Knobs and Levers
Tool-less Plunger Mount
Conical Cylinder Locks
Slots and Keyholes
One-Touch Guide Rail Adjustment
Single-Point Adjustment (Double Lead Screw)
Unitary Lane Spacers
Changepart and Tool Handling
Adjusting Stops and Jacking Screws
Use the Force
Develop and Implement a Program
Process or Project?
Forming the Team
Starting the Team
Who Performs Changeovers
Getting to Work