Presentation on the steps for improving changeovers by reducing time involved

1. Quick Changeovers: The process of getting to SMED

3. Changeover time: Definition The time elapsed between when the last good piece of product A comes off and the first good piece of product B starts. Last good piece of product A First good piece of product B Total setup

4. SMED : S ingle M inute E xchange of D ie Concept that says all setups should and can take less than 10 minutes OTED: One Touch Exchange of Die Concept that says all setups should and can take less than 100 seconds ! What is “World-Class” in Quick Changeovers?

5. What can focusing on QCO do for us? 85% 62% 41% 0% < 100 sec 9% 16% 17% 0% 100 sec – 5 min 5% 12% 20% 5% 5-10 min 1% 7% 12% 20% 10-20 min 0% 3% 10% 26% 20-30 min 0% 0% 0% 19% 30-60 min 0% 0% 0% 30% > 60 min 1988 Estimated 1980 1977 1976 Setup Time

6. Why is Changeover Time Important? Time (minutes) Available Time Process Time Actual Process (Up Time) 0 24 48 72 96 120 168 Sched. D/T Total Available Time Sched. D/T Sched. D/T C/OTime C/OTime Lost Time

9. Step 1:List the current process and times

10. Machine running Machine running Last good piece of product A First good piece of product B Total setup Internal and external elements Step 2: Observe today’s setup

14. BPCS Trans – old roll 34 30 26 28 Cut material Thread material Lift roll /engage chucks Position new roll Retrieve new roll Start Line – ~ 38 mins Operator Log – new roll Stop line – cut paper – tape cores Run new roll to winder Rethread – re-splice roll Start line – Splice Break Lower into cradle Splice new/previous roll Retrieve tape Stop line/ remove cores 38 36 32 24 22 20 18 16 14 12 10 8 6 4 2

15. Step 3: Separate & list internal and external elements. Internal External

16. Internal vs. External… This distinction is a cornerstone of setup reduction: What is the difference between external and internal elements? Internal elements: operations that must be performed while the machine/process is stopped External elements: operations that can be performed while the machine/process is running

17. BPCS Trans – old roll 34 30 26 28 Cut material Thread material Lift roll /engage chucks Position new roll Retrieve new roll Start Line – ~ 38 mins Operator Log – new roll Stop line – cut paper – tape cores Run new roll to winder Rethread – re-splice roll Start line – Splice Break Lower into cradle Splice new/previous roll Retrieve tape Stop line/ remove cores 38 36 32 24 22 20 18 16 14 12 10 8 6 4 2

18. BPCS Trans – old roll 34 30 26 28 Cut material Thread material Lift roll /engage chucks Position new roll Retrieve new roll Start Line – ~ 38 mins Operator Log – new roll Stop line – cut paper – tape cores Run new roll to winder Rethread – re-splice roll Start line – Splice Break Lower into cradle Splice new/previous roll Retrieve tape Stop line/ remove cores 38 36 32 24 22 20 18 16 14 12 10 8 6 4 2

19. Step 4: Convert internal to external Internal External

21. BPCS Trans – old roll 34 30 26 28 Cut material Thread material Lift roll /engage chucks Position new roll Retrieve new roll Start Line – ~ 38 mins Operator Log – new roll Stop line – cut paper – tape cores Run new roll to winder Rethread – re-splice roll Start line – Splice Break Lower into cradle Splice new/previous roll Retrieve tape Stop line/ remove cores 38 36 32 24 22 20 18 16 14 12 10 8 6 4 2

22. Internal elements Machine running Machine running Last good piece of product A First good piece of product B Total setup External elements External elements Setup/changeover With these changes, your new setup/changeover should look like this:

23. Streamlined internal elements Machine running Machine running Last good piece of product A First good piece of product B Total setup External elements External elements Step 5: Streamline the Internal Elements

25. 26 -4 -2 Position new roll Stop line/ remove cores Lift roll /engage chucks Thread material Cut material Splice new/previous roll Lower into cradle Start line – Splice Break Run new roll to winder Stop line – cut paper – tape cores Start Line @ ~20 BPCS Trans – old roll 34 30 28 Operator Log – new roll Retrieve tape Retrieve new roll 38 36 32 20 18 16 14 12 10 8 6 4 2

26. Create parallel steps Internal External

30. Streamlined internal elements Machine running Machine running Last good piece of product A First good piece of product B Total setup Streamlined External elements Streamlined External elements Step 6: Streamline the External Elements

33. BPCS Trans – old roll 34 30 26 28 Cut material Thread material Lift roll /engage chucks Position new roll Retrieve new roll Start Line – ~ 40 mins Operator Log – new roll Stop line – cut paper – tape cores Run new roll to winder Rethread – re-splice roll Start line – Splice Break Lower into cradle Splice new/previous roll Retrieve tape Stop line/ remove cores 38 36 32 24 22 20 18 16 14 12 10 8 6 4 2

34. 26 -4 -2 Position new roll Stop line/ remove cores Lift roll /engage chucks Thread material Cut material Splice new/previous roll Lower into cradle Start line – Splice Break Run new roll to winder Stop line – cut paper – tape cores Start Line @ ~20 BPCS Trans – old roll 34 30 28 Operator Log – new roll Retrieve tape Retrieve new roll 38 36 32 20 18 16 14 12 10 8 6 4 2

38. Step 10: Kaizen the C/O! SMED/Quick Changeover

39. SMED “Simulation” Situation: You leave work, after a long day, you’re tired and anxious to get home to dinner with your family. It’s raining (or snowing) out, the traffic is heavy, and you’re late. You are driving along the interstate, and suddenly discover your have a flat tire. Exercise: As a group, list the detailed steps you must go through to change your flat tire and get back on the road again.

40. SMED “Simulation” Situation: You leave work, after a long day, you’re tired and anxious to get home to dinner with your family. It’s raining (or snowing) out, the traffic is heavy, and you’re late. You are driving along the interstate, and suddenly discover your have a flat tire. Exercise: Ask the group how long this process typically takes. Get several answers.

41. SMED “Simulation” Situation: Now we’ll take a look At how “professionals” change tires, And how long it takes them.