Step 5 – Reduce Changeover Times
Step 5 is really focused on reducing process downtime. One of the largest causes of downtime in a manufacturing facility is machine changeovers. The time that a piece of equipment is being changed from running one product to run the next product it is unavailable for production. This is lost production time which cannot be recovered. The way forward to reduce this changeover downtime is to implement a Quick Changeover.
What is a Quick Changeover?
A Quick Changeover is a improvement process using the SMED concept for reducing equipment downtime. The definition of a changeover is the time between the last good part of the current run until the first good part off the next run. The time taken to set up a process is non-productive and therefore, non value added from a customers perspective. It takes longer to manufacture components because orders have to wait until the equipment can produce a good part before an order can be started and the work completed. Lead time increases because of long changeover times.
What are the steps in a Quick Changeover?
There are four steps to implementing SMED:
1. Document and record a changeover to identify the activities
2. Separate activities into internal and external elements
3. Convert internal into external elements
4. Streamline all aspects of the changeover process
What affect will implementing SMED have on production?
Long changeover times force a business to manufacture large batches being product to compensate for the downtime. Implementing quick changeovers using SMED will reduce the amount of time to set up a machine. This will reduce lead time and increase production hours.
Quick Changeover Video
In this short video, Chris Turner – Lean Mfg. Coach gives a brief explanation about the Quick Changeover process.