Kaizen for Quick Changeover: Going Beyond SMEDChangeovers in 3 minutes or less! Picking up where Dr. Shingo's Single Minute Exchange of Die left off, this book streamlines the process even further to reduce changeover time, while simultaneously cutting staffing requirements in half. To instruct on how to achieve quick changeover in virtually any type of production environment, the book includes— The book begins by outlining the tactical principles for improving the three phases of the changeover procedure. Next it demonstrates how to improve changeover on a processing line. All of the ideas presented are based on kaizen improvements, which require very little, if any, expenditure. Process razing and the implementation of one-piece flow are also examined as means to eliminate wasteful transportation and searching. |
Contents
Processing Line Changeover Improvement Approaches | 65 |
39 | 98 |
Improvement Case Studies | 149 |
31 | 156 |
Single Changeover in the Steel Forging Industry | 163 |
13 | 174 |
Zero Changeover for Transfer Machines | 175 |
Changeover Improvement Steps for the Process Industry | 201 |
Zero Changeover for PCB AutoInserters | 219 |
Zero Changeover for a Sheet Metal Factory | 235 |
Zero Changeover for PlasticMolding Machines | 245 |
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Common terms and phrases
achieving zero changeover Adjustment waste air hose Analysis Chart assembly line auto-clamp auto-feed automated block gauges bolster Boltless Fastener cassette changeover improvement changeover loss changeover operations changeover workers Chapter clamp clamping tool cleaning Company Daihatsu deburring defects devices Diagram Die Attachment electronic kanban equipment external changeover fastening bolts fastening height handle improvement group improvement plans improvement team insert Install inventory Kaizen kanban lower manual materials ment method minutes operation analysis Operation Combination Chart P-Q analysis Part-specific Capacity Worktable position pre-changeover press press Press Technology problem process razing processing line product models production line reduce changeover removing and attaching replacement robot roller conveyor rotor processing sequence Setup waste shown in Figure shows single changeover Small Press specialized changeover carts spot welding Standard Operation Chart Standard Operation Combination standby waste Step storage Table target Toyota production system types of waste U-shaped cell upper Waste Elimination Chart workpiece