1. Quick Changeovers
Definitions
Analysis and Methods
GEOP 4316

2. Definitions

3. 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%)

4. Definitions Setups can relate to the sequence

5. Definitions Setups in other environments

6. slideshare

7. slideshare

8. 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

9. 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).

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

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

12. 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

13. Analysis and Methods

14. Analysis and Methods
A continuous improvement process

15. 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

16. Analysis and Methods