UNCLASSIFIED / FOUO                       National Guard                      Black Belt Training                         ...
UNCLASSIFIED / FOUOCPI Roadmap – Improve                                                           8-STEP PROCESS         ...
UNCLASSIFIED / FOUO Changeover Definition        The amount of time taken to change      equipment from the Last Good Part...
UNCLASSIFIED / FOUO Traditional vs. CPI Thinking          Traditional Thinking           Changeovers cause downtime     ...
UNCLASSIFIED / FOUO Why Quick Changeover?                       Shorter Changeover Times                      More Frequen...
UNCLASSIFIED / FOUO Internal vs. External      The first task is to recognize that there     are two essentially different...
UNCLASSIFIED / FOUOChangeover Activities          Internal Activities                An activity that must be performed ...
UNCLASSIFIED / FOUO Improvement Steps  1.      Identify changeover activities and document the          process (time each...
UNCLASSIFIED / FOUO Internal vs. External Quiz     Possible CT Scan Changeover Steps:                          Which are  ...
UNCLASSIFIED / FOUO Internal vs. External Quiz   Possible CT Scan Changeover Steps:                       Internal        ...
UNCLASSIFIED / FOUOImprovement Steps        1.      Identify activities and document the process.        2.      Separate ...
UNCLASSIFIED / FOUOConverting Internal to External    Prepare operating conditions prior to changeover           Preheat...
UNCLASSIFIED / FOUO Improvement Steps        1.      Identify activities and document the process.        2.      Separate...
UNCLASSIFIED / FOUO Reduce All Remaining Activities          Perform Parallel Operations          Improve Clamping Mecha...
UNCLASSIFIED / FOUOPit Stop Photo                      Team with Pre-assigned Tasks         Placement Clearly             ...
UNCLASSIFIED / FOUO Takeaways          Remember Safety at all times!!!          Change internal to external then reduce ...
UNCLASSIFIED / FOUO        What other comments or questions                  do you have?                                 ...
Upcoming SlideShare
Loading in...5
×

NG BB 45 Quick Change Over

1,632

Published on

Published in: Education, Business, Technology
0 Comments
0 Likes
Statistics
Notes
  • Be the first to comment

  • Be the first to like this

No Downloads
Views
Total Views
1,632
On Slideshare
0
From Embeds
0
Number of Embeds
0
Actions
Shares
0
Downloads
247
Comments
0
Likes
0
Embeds 0
No embeds

No notes for slide

NG BB 45 Quick Change Over

  1. 1. UNCLASSIFIED / FOUO National Guard Black Belt Training Module 45 Quick Changeover UNCLASSIFIED / FOUO
  2. 2. UNCLASSIFIED / FOUOCPI Roadmap – Improve 8-STEP PROCESS 6. See 1.Validate 2. Identify 3. Set 4. Determine 5. Develop 7. Confirm 8. Standardize Counter- the Performance Improvement Root Counter- Results Successful Measures Problem Gaps Targets Cause Measures & Process Processes Through Define Measure Analyze Improve Control TOOLS ACTIVITIES •Brainstorming • Develop Potential Solutions •Replenishment Pull/Kanban • Develop Evaluation Criteria •Stocking Strategy • Select Best Solutions •Process Flow Improvement • Develop Future State Process Map(s) •Process Balancing • Develop Pilot Plan •Standard Work • Pilot Solution •Quick Change Over • Develop Full Scale Action/ •Design of Experiments (DOE) Implementation Plan •Solution Selection Matrix • Complete Improve Gate •‘To-Be’ Process Mapping •Poka-Yoke •6S Visual Mgt •RIE Note: Activities and tools vary by project. Lists provided here are not necessarily all-inclusive. UNCLASSIFIED / FOUO 2
  3. 3. UNCLASSIFIED / FOUO Changeover Definition The amount of time taken to change equipment from the Last Good Part of a process to the First Good Part of the next process Clock Time, not Labor Time! UNCLASSIFIED / FOUO 3
  4. 4. UNCLASSIFIED / FOUO Traditional vs. CPI Thinking  Traditional Thinking  Changeovers cause downtime  Changeovers cause poor utilization, defects & scrap  Big Batch Size desirable - “The Bigger, the Better” (less changeovers)  CPI Thinking  Quick changeovers decrease downtime  Well designed changeovers decrease waste  Quick changeovers (with small batches) Increases Flexibility UNCLASSIFIED / FOUO 4
  5. 5. UNCLASSIFIED / FOUO Why Quick Changeover? Shorter Changeover Times More Frequent Changeovers Smaller Batch Sizes Shorter Lead Times Increased Combat Capability! UNCLASSIFIED / FOUO 5
  6. 6. UNCLASSIFIED / FOUO Internal vs. External The first task is to recognize that there are two essentially different components of any changeover, Internal Activities and External Activities. UNCLASSIFIED / FOUO 6
  7. 7. UNCLASSIFIED / FOUOChangeover Activities  Internal Activities  An activity that must be performed while the machine or process is turned off (no product)  Example – Refuel plane on the ground  External Activities  An activity that can be performed while the machine or process is turned on (producing product)  Example – Refuel plane in the air UNCLASSIFIED / FOUO 7
  8. 8. UNCLASSIFIED / FOUO Improvement Steps 1. Identify changeover activities and document the process (time each step). 2. Separate Internal activity from External activity External Internal External UNCLASSIFIED / FOUO 8
  9. 9. UNCLASSIFIED / FOUO Internal vs. External Quiz Possible CT Scan Changeover Steps: Which are 1. Machine is turned off as scan ends Internal & 2. IV is removed from the patient 3. Patient is moved off of scan bed Which should 4. Patient is removed from CT scan room be External? 5. New Patient is identified off of CT scan schedule 6. New Patient is brought into CT scan room 7. Patient identification is verified 8. CT Scan procedure is explained to patient 9. Type of Scan is verified from Physician Orders 10. IV is started on new Patient 11. Patient is placed on CT scan bed 12. CT Scan machine is turned on and scan begins Adapted from “A Lean Guide to Transforming Healthcare”, Zidel, 2006 UNCLASSIFIED / FOUO 9
  10. 10. UNCLASSIFIED / FOUO Internal vs. External Quiz Possible CT Scan Changeover Steps: Internal 1. Machine is turned off as scan ends External 2. IV is removed from the patient 3. Patient is moved off of scan bed 4. Patient is removed from CT scan room 5. New Patient is identified off of CT scan schedule 6. New Patient is brought into CT scan room 7. Patient identification is verified 8. CT Scan procedure is explained to patient 9. Type of Scan is verified from Physician Orders 10. IV is started on new Patient 11. Patient is placed on CT scan bed 12. CT Scan machine is turned on and scan begins Adapted from “A Lean Guide to Transforming Healthcare”, Zidel, 2006 UNCLASSIFIED / FOUO 10
  11. 11. UNCLASSIFIED / FOUOImprovement Steps 1. Identify activities and document the process. 2. Separate Internal from External activity 3. Convert Internal to External UNCLASSIFIED / FOUO 11
  12. 12. UNCLASSIFIED / FOUOConverting Internal to External Prepare operating conditions prior to changeover  Preheat molds or dies  Prepare Patient or Care-givers  Prepare service materials or providers  Pre-adjust parts Use intermediary sets  Preset tools  Position dies Standardize necessary functions  Change the fewest parts possible  Minimize or eliminate adjustments UNCLASSIFIED / FOUO 12
  13. 13. UNCLASSIFIED / FOUO Improvement Steps 1. Identify activities and document the process. 2. Separate Internal from External activity 3. Convert Internal to External 4. Reduce all remaining activities. UNCLASSIFIED / FOUO 13
  14. 14. UNCLASSIFIED / FOUO Reduce All Remaining Activities  Perform Parallel Operations  Improve Clamping Mechanisms  One turn clamps  One motion methods  Eliminate all adjustments  Numerical Settings vs. “Feel”  Automate activities where appropriate UNCLASSIFIED / FOUO 14
  15. 15. UNCLASSIFIED / FOUOPit Stop Photo Team with Pre-assigned Tasks Placement Clearly Defined Quick Connect & Tools Properly Positioned Prior Disconnect Devices to Arrival UNCLASSIFIED / FOUO 15
  16. 16. UNCLASSIFIED / FOUO Takeaways  Remember Safety at all times!!!  Change internal to external then reduce all activities  Standards are standards, they are not flexible  Standardize all changeover operations UNCLASSIFIED / FOUO 16
  17. 17. UNCLASSIFIED / FOUO What other comments or questions do you have? UNCLASSIFIED / FOUO 17
  1. A particular slide catching your eye?

    Clipping is a handy way to collect important slides you want to go back to later.

×