quick changeover basics

Quick Changeover Basics

This material is provided by Industrial Solutions, Inc. and is intended for internal use only. Any reproduction or re-use outside of the purposes described must be

authorized by Industrial Solutions, Inc

Industrial Solutions, Inc., 2010

Definition of Changeover Time

• The time between

the last good

piece off the

current run and

the first good

piece off the next

run.

Traditional Changeover

Before improvements, basic setup tasks and related time breakdowns:

Percent of time of changeover

50%

15%

30%

5%

Preparation, after-process adjustment, checking, storing, and moving materials, parts, and tools

Removing and mounting parts and tools

Machine measurements, settings, and calibrations

Trial runs and adjustments

The Best Changeover is

No Changeover

Traditional Changeover and the Wastes of Lean

Traditional Changeover TasksPreparation

andAdjustments

Removingand

Mounting

Measurements, Settings,

Calibrations

Trial Runsand

Adjustments

Overproduction

Waiting

Transportation

Processing

Inventory

Defects

Motion

People

Eig

ht

Was

tes

Changeover Improvement Process

Analyze

Implement

Standardize

Lean Basics

Document

Traditional Changeover

Day 1 Day 2 Day 3 Day 4 Day 5

Hours

Traditional Changeover2-Hour Changeover (CO)


Hours

2 hours

Weekly CO time: 10 hours

Run time: 30 hours

Available time: 0 hours

2 hours2 hours2 hours2 hours

EDCBA

Quick Changeover

3-Minute Changeover


Hours

Quick Changeover

3-Minute Changeover


Hours

E

Weekly CO time: 75 minutes

Run time: 30 hours

Available time: 8.75 hours

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What Does Quick Changeover Involve?

• Planning

• Practice

• Innovation

• Standardization

• Continuous Improvement

Impact of Quick Changeover

Key Benefit

s

Increased Accuracy,Improved Quality

Decreased Costs,Increased Capacity

Reduced Lead Time

Flexible Responseto Customer Needs

Improved On-Time Delivery

Document the Current Changeover

• Document all the tasks or elements that make up the current changeover

• Capture and visually organize data about the changeover

• Identify changeover improvement priorities

Analyze

Implement

Standardize

Lean BasicsSMED

Document

How Do We Improve

• A systematic approach is needed

• Single Minute Exchange of Die (SMED)

• Developed in the 1950’s in Japan

• The goal is to get every changeover under 10 minutes (single digit)

• You can not get there in one step or one event

The SMED Approach

• Identify internal vs. external changeover tasks

• Analyze each task’s real purpose and function

• Focus on no/low cost solutions

• Aim to eliminate changeover time

Three Stages of SMED• Separate Internal and

External Setup

• Convert Internal Setup to External Setup

• Streamline Internal and External Elements

Setup Reduction

SMED: Separate Internal and External Setup

• Develop and implement changeover checklists.

• Perform function checks on parts and tools.

• Reduce transportation of tools, parts, and materials.

• Separate Internal and External Setup



Setup Reduction


• Develop specific checklists for every piece of equipment and major process.

- What is needed?- Where is it needed?- Who needs to do what?- How long should it take?- What are the proper operating conditions?- What are the correct settings for the next operation?

• Keep checklists up-to-date and visible to all.

• Use checklists consistently prior to every changeover.

Develop and Implement Changeover Checklists


• Are all of the changeover materials in good working order?

- Tools- Parts- Jigs- Fixtures

• Have all materials been checked far enough in advance to allow time for repairs?

Perform Function Checks on Parts and Tools


• Reduce non-value added movement of changeover parts, tools, and materials

• Transport changeover materials before the machine shuts down


Reduce Transportation of Tools, Parts, and Materials

No/Low Cost Solution: Reduce Transportation

• Prepare operating conditions in advance

• Standardize functions

• Use intermediary jigs




Setup Reduction

SMED: Convert Internal Setup to External Setup


• Preheat parts and tools to required temperature before they are needed

• Achieve correct pressure levels before start-up

• Position materials near point-of-use

Prepare Operating Conditions in Advance


• Eliminate time-consuming adjustments

• Focus on functions such as dimensioning, securing, gripping, and centering

• Replace the fewest possible parts by changing the way we perform the function

Standardize Functions

No/Low Cost Solution: Standardize Functions

Die Plate Adjusts Shut Height


• Design and build standard-sized, removable plates or frames

• Externally attach and adjust die/parts

• Eliminate internal adjustments to individual parts during changeover

Use Intermediary Jigs

SMED: Streamline Internal and External Elements

• Implement parallel operations

• Eliminate the need for adjustments

• Use functional clamps

• Mechanize functions




Setup Reduction

SMED: Streamline Internal Elements

• Divide changeover tasks between two or more people.

• Maintain detailed changeover procedures.- Who’s doing what?

- Sequence of tasks

- Required time for each task

• Reduce wasted motion, avoid confusion, and ensure worker safety.

Implement Parallel Operations


• Use visual marks to indicate correct settings

• Create “quick set” mechanisms to handle different functions

• Install fixed stops to indicate where a part should be positioned

Eliminate the Need for Adjustments

No/Low Cost Solution: Use of Numerical Scales

Numerical Scale

No/Low Cost Solution: Use of Positioning Pins

Positioning Pins

Positioning Pins

Setup Reduction Tools

• Cartridges

• Standard work (dance cards)

• Quick release handles

• Off line setups

• Water spider (pit crew)

• Setup documentation

• Improved machine reliability


• One-turn methods

• One-motion methods

• Interlocking methods

Use Functional Clamps

No/Low Cost Solution: One-Turn Methods

Pear-Shaped Hole Method

Tighten Here

Attach and Remove

Here

No/Low Cost Solution: One-Turn Methods

Wing Nut Method

No/Low Cost Solution: One-Motion Methods

Cam Method


• Use to fine tune, not significantly reduce, setups

• Consider only when changeover reaches the three-minute range


Mechanize Functions

SMED: Streamline External Elements

Maintain a Visual, Organized Workplace




Setup Reduction

Three Stages of SMED• Separate Internal and

External Setup



Setup Reduction

• Distinguish between internal and external setup tasks.

• Identify and apply proven techniques to convert internal to external setup tasks.

• Develop streamlined processes for internal and external setup tasks.

• Create an improved changeover process.

Analyze

Implement

Standardize

Lean BasicsSMED

Document

Analyze Changeover Tasks and Identify Improvements

Analyze

Applying SMED

• Complete Setup Analysis Chart.

• Develop no/low cost solutions.

• Streamline, streamline, streamline!

• Create an improved changeover process.

Analyze Changeover TasksIdentify Improvements

Implement

• Implement Quick Changeover improvements

• Monitor and document results

Analyze

Implement

Standardize

Lean BasicsSMED

Document

Implement Improvements and Monitor Results

• Develop a plan to standardize improvements

Analyze

Implement

StandardizeLean Basics

SMED

Document

Standardize the Improvements

Standardize

Benefits of Quick Changeover

Key Benefit

s

Increased Accuracy,Improved Quality

Decreased Costs,Increased Capacity

Reduced LeadTime

Flexible Responseto Customer Needs

Improved On-Time Delivery

quick changeover basics

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