Quick Changeovers Definitions Analysis and Methods GEOP 4316

Definitions

Definitions Setup: time between the last good product of a production run to the first good product of the next production run Preparation (25%) Setup actions (10%) Adjust-ments (15%) Trial Runs (50%)

Definitions Setups can relate to the sequence https://www.allaboutlean.com/changeover-sequencing-part-1/ice-cream-change-over-matrix-flavor-and-cone/

Definitions Setups in other environments http://publications.lib.chalmers.se/records/fulltext/241301/241301.pdf http://www.surgerymanagement.com/presentations/rapid-operating-room-turnover1.php

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Definitions Quick Changeover A method that provides a rapid and efficient way of converting a process from running the current product to running the next product. This rapid changeover is key to reducing production lot sizes and thereby improving flow (Mura). Changeover time = waste of waiting Large setups require large batches = overproduction/ inventory wastes http://en.wikipedia.org/wiki/Single_Minute_Exchange_of_Die

Definitions Quick Changeover =SMED SMED : Single minute exchange of die Applicable primarily for diversified and low volume production. One of the main difficulties: Frequent setup operations. Calibration Switching of tools or dies Perform setup operations in less than 10 min (single digit). http://en.wikipedia.org/wiki/Single_Minute_Exchange_of_Die

Definitions Die: A die is a specialized tool used in manufacturing industries to cut or shape material mostly using a press. 

Definitions Mold: Hollowed out block to be filled with liquid or pliable material.

Analysis and Methods 2 types of setup operations: Internal operations: Activities that can be performed ONLY when the machine is STOPPED. Mounting or removing dies. External operations: Activities that can be done WHILE the machine is in OPERATION. Transporting old dies to storage or conveying new dies to machine. Improvements made by converting Internal Operations to External Operations

Analysis and Methods http://setupreductiononline.com/smed-seperating-external-and-internal-activities/

Analysis and Methods A continuous improvement process

Analysis and methods Typical wastes in setups Searching for instructions or documents Searching for tools Transporting and aligning tools/ dies Waiting for materials Searching for bolts, washers Searching for measuring instruments

Analysis and Methods https://www.vorne.com/solutions/reduce-changeover-times.htm