Quick Changeover
Kaizen Event
A
Kaizen Blitz is a very intensive and focused approach to Process
Improvement. A specific set-up process
is selected for analysis by a multi-functional team of people. The team analyzes a specific set-up process
by use of videotape. The videotape
provides an objective means for the team members to "step out of the
process", and see it more clearly.
The Set-up Reduction team will define each step of the process, as well
as time each step.
Thereafter,
the team will challenge the current process and identify opportunities for
improvement. A review of Set-up
Reduction concepts and techniques is integrated throughout the exercise. These concepts include, but are not limited
to: external vs. internal activities; component and tool reduction; quick
changeover fasteners; teaming concepts; point of use storage of materials. A new set-up process is designed, and its
performance projected.
Whenever
possible, elements of the new process are implemented during the Kaizen Blitz,
and the results verified. However, more
typically, additional time is required to implement the various improvements
identified. Changes to equipment, tools,
fixtures, etc. all take time, and some expense.
Therefore, confirmation of the results is usually performed at some
point in time in the future, typically within 30-60 days.
A three day Kaizen event is conducted in the production
area on a particular set-up process. A
team of internal personnel is identified, and is facilitated through a six step
approach to implement Set-up Reduction concepts. Education in Set-up Reduction concepts is
integrated throughout the event. The
Set-up Reduction Kaizen will result in; a documented set-up procedure;
projected performance of the new set-up process; a videotape of the old and new
set-up process that can be used for training purposes; an implementation plan
and actions list. A 50% - 95% reduction
in set-up time is typical.
Typical 3-Day Agenda
Pre-event: Scoping:
identify subject of the event, determine current set-up time
Day 1: Education in basic concepts
Observe
and Videotape actual set-up process
Analyze
process, identify process steps and times
Identify
external vs. internal activities
Day 2: Design new set-up process and project performance
Develop
Implementation Plan
Initiate
changes
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Typical 3-day Agenda (continued)
Day 3: Complete changes
Re-run set-up, verify results
Develop follow-up plan
The duration of the event
will vary based on the current time to set-up or changeover. For example, it will require more time to
document, analyze and re-design a 6 hour changeover process than a 2 hour
process. The actual changes possible to
implement during the event will depend on the nature of the changes. For example, some may require physical
changes to the equipment or tooling that is just not possible during the event
itself. Such items will be included in
the follow-up plan.
Typical Deliverables
·
A cross
functional team of people who will understand QCO concepts and the methodology
used to implement them, and who will be experienced in their actual
application.
·
A proposed and
documented set-up process, with supporting analysis.
·
Projected
benefits of the proposed process, per the performance measures used. These benefits will be verified by the end of
the event whenever possible.
·
Actions List and
implementation plan to assist in follow-up, if physical changes were not possible
during the Kaizen event.
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Management Associates Tele: 856-235-8051 • Website:
cma4results.com |
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Quick Changeover
One
Day Workshop
One
of the greatest impediments to flow is the need to changeover equipment from
one part or product to another. Lengthy
changeovers are one of the key drivers for large batch sizes, which in turn
increase the amount of inventory a company must carry. Still further, quality defects, scrap or
wasted material is often another outcome of lengthy changeovers. However, many companies have still not
applied the common sense concepts of quick changeover or what has also been
called “Single Minute Exchange of Die (SMED)”.
Therefore, they are reluctant to challenge their historic big batch
processing ways.
This workshop will review
the six-step methodology that is used to reduce changeover or set-up time. This methodology typically makes use of video
taping and other documentation techniques that allow for a thorough analysis of
the current process. Video taping
techniques will be covered as will specific QCO concepts. These include how to measure true changeover
or set-up time, distinguishing between “internal” and “external” activities,
methods to convert internal to external, streamlining techniques, and teaming
approaches.
The workshop makes use of a
simulation to enhance the learning experience.
The participants will be able to apply most of what they have learned to
the simulated changeover process.
Numerous photographed examples from a wide assortment of industries will
also be provided.
Interestingly, quick
changeover techniques have been applied to non-production processes such as the
month-end closing process found in many companies.
Duration: One day
Who should attend: anyone involved in the changeover
of production equipment can benefit by attending this workshop including
operators, set-up technicians, material handling, quality personnel, scheduling,
supervisors and managers. Even non-production
personnel can benefit by this workshop as changeovers of various types exist in
the office environment.
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Management Associates Tele: 856-235-8051 • Website:
cma4results.com |
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