The Quick Changeover Playbook

A Step-by-Step Guideline for the Lean Practitioner

Chris A. Ortiz

• Publisher: Productivity Press
• Year: 2016
• ISBN:
  9781498788328
• Edition: 1
• Topic: Business
• Subtopic: Operations
• Index: Business

This book covers the basics of setup reduction and quick changeover and data collection. It outlines the first pass of waste reduction through the implementation of the visual workplace and layout improvements. The book covers two quick changeover concepts: intermediate tooling and one-turn methods.

Chapter 1

Setup and Quick Changeover

Introduction

Organizations that produce product in equipment-based environments should have setup reduction as a cornerstone of their Lean journey. A good understanding of the concepts and tools is needed as many people confuse the definitions of setup reduction and quick changeover. This chapter creates a baseline for understanding the concepts so you can be prepared to train and implement effectively with your team.

Downtime by definition is non–value added. It is the waste of waiting, as the machine is “waiting” to be turned on—whether from breakdowns, planned maintenance, or in the case of this playbook, for the setup to be complete.

Setup is the act of performing tasks at the end of a production run to the start of another production run. Changeover is part of the overall setup activities. To help explain, let us start with describing the four steps of a setup.

1. Preparation
2. Removing and mounting parts
3. Measurements
4. Trial runs and final adjustments

Preparation

• Retrieving material, supplies, and parts
• Reviewing paperwork
• Retrieving tools
• Retrieving tooling and fixtures
• Ensuring parts, tools, and tooling are functional and working properly
• Performing simple cleaning of equipment

Removing and Mounting Components in Machine (Changeover)

• Disconnecting fixtures, part(s), and material
• Connecting fixtures, part(s), and material
• This step is the changeover.

Measurements

• Measuring, calibrating to prepare for a production run
• Centering, dimensioning, measuring temperature/pressure, and so on
• Checking settings

Trial Runs and Final Adjustments

• Test piece to verify setup is complete
• Make adjustments as needed
• Potentially make a second test piece

Four Setup Steps

External and Internal Setup Steps

There are two different types of work performed during a setup: external and internal.

External

External work is performed when the machine is running. Generally when it is producing product, the machine operator is gathering items for the next production run. This is an id...

Table of contents

• Cover
• Title Page
• Table of Contents
• How to Use This Playbook
• Introduction
• Chapter 1: Setup and Quick Changeover
• Chapter 2: Data Collection
• Chapter 3: 5S and Layout Improvements
• Chapter 4: Intermediate Tooling and One-Turn Methods
• Chapter 5: Visual Management
• Chapter 6: After Improvements
• Conclusion
• Definition of Terms
• About the Author