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
Steps Toward Zero Changeover | 13 |
A Formula for Achieving Zero Changeover | 29 |
Processing Line Changeover Improvement Approaches | 65 |
Making Inexpensive Improvements to Reduce Staffing Needs | 101 |
Steps for Improving New Processing Lines | 121 |
Improvement Case Studies | 149 |
Single Changeover in the Steel Forging Industry | 163 |
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
achieve zero changeover Adjustment waste air hose Analysis Chart assembly line auto-clamp auto-feed automated block gauges bolster cassette changeover improvement changeover loss changeover operations changeover procedures changeover workers Chapter chute clamp clamping tool cleaning Company Daihatsu defects devices Diagram Die Attachment die-cast electronic kanban equipment external changeover fastening height fastening tools handle improvement group improvement plans improvement team insert Install inventory Kaizen kanban materials ment method minutes operation analysis Operation Combination Chart P-Q analysis Part-specific Capacity Worktable plastic-molding machines position pre-changeover preheating problem process razing processing line reduce changeover removing and attaching roller conveyor sequence Setup waste shown in Figure shows single changeover slide small improvements solenoid valves specialized changeover carts Standard Operation Chart Standard Operation Combination standby waste Step stopper storage swarf Table target Toyota production system types of waste U-shaped cell Waste Elimination Chart workpiece