Achieving Lean Changeover: Putting SMED to Work by John R. Henry

By John R. Henry

Defined because the overall technique of changing a line or procedure from one product to a different, changeover won't basically aid your company enhance caliber and adaptability, however it will keep millions and occasionally even tens of hundreds of thousands of greenbacks in keeping with hour.

Achieving Lean Changeover: placing SMED to paintings is concerning the useful implementation of the only minute trade of die (SMED) philosophy constructed by way of Shigeo Shingo at Toyota. even if the booklet is mainly approximately changeover of producing, packaging, and meeting techniques, the final strategies and examples also are acceptable in lighter industries that require turnover of processes—including airways, hospitals, working rooms, and nutrients service.

Filled with sensible examples, the e-book stocks confirmed tools that may assist you convert changeover downtime to effective uptime. It explains why lowering changeover time is critical financially and gives a dependent method that will help you determine and enforce development opportunities.

The writer addresses either the equipment matters with changeover/ SMED and the linked operational matters comparable to bills, ready occasions, fabric circulate, documentation, and product/component layout. He additionally devotes a bankruptcy to discussing, intimately, tips to calculate the price of changeover downtime, a space that is still a secret to many.

Taking a holistic method of changeover, the textual content encompasses a bankruptcy dedicated to organizing changeover advancements, conserving them heading in the right direction, and constructing and enforcing a proper changeover aid application. featuring time-tested tools and functional examples from numerous industries, it provide you with the chance to lessen changeover time and price and supply your company with the flexibleness had to higher fulfill your shoppers in 3 very important dimensions: product sort, responsiveness, and price.

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Extra resources for Achieving Lean Changeover: Putting SMED to Work

Sample text

PURPOSE 2. 3 Responsibility 3. MATERIALS 4. TOOLS 5. DEFINITIONS 6. 1 7. DOCUMENTATION 8. 2 Machine layout drawings 9. REFERENCES 10. CHECKLIST At the top of each page is a header block. This header block contains certain standard information that will appear on every page of the SOP: Title: This is the title of the SOP. It should be descriptive but brief; for example, Changeover—Press #1 Page number of total: This provides both the page number being viewed as well as a count of the total pages in the document.

Lean changeover is certainly a good business tactic. It will reduce costs in much the same way as turning off unnecessary lights will. The cost of changeover downtime, discussed in depth in Chapter 2, is usually thousands or tens of thousands of dollars per hour, and any reduction will have significant impact on plant operating costs. More importantly, lean changeover is a strategy that can and has allowed companies to leapfrog their competition. Toyota is one famous example. Another company was a failing division of a large multinational scheduled for shutdown in the late 1980s.

Still, nothing is perfect and reducing opportunities for accidents will help reduce them. Some plants use mechanics to perform equipment changeover. Time spent on changeover is time not spent on preventive or repair maintenance. Time spent on changeover is time not spent on developing and implementing improvements. Time spent on routine, repetitive tasks such as changeover is time spent not fully utilizing the talents and skills of the mechanics. LCO will free up their time and allow better utilization.

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