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How to reduce changeover loss

In any SME manufacturing organizations, one of the major causes for low plant utilization is changeover loss.In this presentation, using SMED methodology, step by step process is given to reduce the changeover loss.Also shared the real examples of changeover loss reduction in various manufacturing industries using SMED concept.Hope this is useful for any organization struggling with low plant utilisation due to changeover loss..

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How to reduce changeover loss

  1. 1. How to reduce “Changeover time loss” and improve plant utilization
  2. 2. • Definition of “Changeover Time Loss” • Business and Operational impact of “Changeover Time Loss” • Concept of “SMED”( Single Minute Exchange Dies) • Process steps in “SMED ” execution • Case study Examples Learning Objectives…
  3. 3. Last good piece of product A First good piece of product B Changeover Time=3.5 hrs 6.15 am 10.45 am 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.
  4. 4. Typical Types of changeover in Operations  Die Changeover in Press, Casting ,Moulding machines Tool insert change in CNC, SPM machines Colour change in Paint and Powder coating  Model changeover in Assembly All changeover leads to Equipment utilization loss in turn affects the delivery, productivity and cost
  5. 5. Significance of changeover loss..  Increase in variety Pressure on inventory reduction Speed / Flexibility expectation  Profitability through Utilization Improvement •Increase in lead-time ,managing through WIP & increase in working capital •Large batch size –side effect on quality issues ,space, handling etc •Safety issues due to non standardized process •Low flexibility for servicing multiple product
  6. 6. Background & History • SMED concept by Shigeo Shingo, Japanese consultant • Concepts originated around 1950-60’s and internalized in Toyota • Continuously evolved from SMED to OTED
  7. 7. World-Class Quick Changeover Methodologies… SMED: Single Minute Exchange of Die 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!
  8. 8. Traditional vs SMED based Changeover Traditional changeover SMED based changeover Say 20 min per Tyre Say 20 sec for four Tyre
  9. 9. Traditional Changeover Process… • Preparation of tools / dies and ensure in working condition • Move to machine • Removal of dies from machine • Placing of dies • Setting all process control • First trial • Adjustment • Take trial • Final good piece production More of “Sequential” Inconsistency in Process &Time More Adjustment and Trial
  10. 10. SMED Changeover Process… • Emphasis more on parallel activities than sequential • Changeover process by set of cross functional experts than one • Predefined work and collaboration of cross functional team • Focus more on housekeeping and visual management practices • Standardization as much as possible
  11. 11. SMED Methodology Existing changeover process Improvement steps Observe and Record the elements Identify Internal and External Elements Convert Internal elements to External elements Improve External Elements Improve Internal Elements Document Internal & External Elements and Standardize
  12. 12. Observe and Record Elements…  Video recording is ideal to understand and explain Sample Elemental Recording data Time on Element description Duration (Min) 9.15 am Machine stopped for die setting 0 9.15-9.30 am Operator is waiting for supervisor's instruction 15 9.30 am Temporary operator to clean flashes from machines/ die 2 9.32 am coolant hose removal 5 9.37 am Temporary operator stuck with removing hose removal ; need assistance 2 9.39 am Senior employee came in to assist 1 9.40 am Bring Chain / hook to lift 2
  13. 13. Identify Internal and External Elements Internal elements: Activities that must be performed while the machine is stopped Example :  Placing the die inside the bed Tightening the die with machine bed External elements: Activities that can be performed while the machine is running Example : Positioning the crane and tools in front of the machine for loading
  14. 14. Identify Internal and External Elements (Example) Remove 4 off bolts on rear side using spanner / pipe rod 5 Internal Remove 4 off bolts on front side using spanner / pipe rod 3 Internal completed removing ejector pin 4 Internal Lifting starts Internal perm employee removes bolt from machine guide ways 2 Internal maintenance team checks on sprayer 10 Internal CL removes flash from bolt guide ways and air clean 5 Internal change plunger / sleeve by perm employee Internal 5 times went to get wooden block , screw driver , ejector rod , waste cloth 14 External filing and removing flashes from plunger block - 1 min 1 External completes fixing plunger block 1 Internal Maintenance team removes sprayer 6 Internal fixing plunge block with support of CL and remove wooden block 1 Internal perm employees tries to fix hook in cyl head die which was kept in hand pallet 13 Internal it is loose and call die maintenance person External remove core / cavity die from hand pallet and joining both External die maintenance person air clean the screw hole External fixes 2 eye bolt in the die and connect with chain 2 Internal
  15. 15. Convert Internal elements to External Elements Convert as much as possible Internal Elements into External Elements  Proper Housekeeping –Location for everything Eliminate Searching  Pre Arrangement of tools / dies  Spares Management  All experts –Being near to machine when changeover takes place Make Visual marks / identification as much as possible and avoid trials
  16. 16. Improve External Elements  Housekeeping-Location for all items Visual Identification for all items Colour Coding Standard set up process Checklist for each die setting
  17. 17. Improve Internal Elements • Create Parallel steps (eg removing bolts) • Reduce complexity and eliminate waste  Use functional fixtures and jigs • levered or one-turn fasteners • interlocking wedge or slot  Eliminate adjustments • use angle and flat • use preset pins, guides, notches etc.
  18. 18. Look for opportunities in Internal Elements..
  19. 19. Document and standardize ..  Create Checklist for each die change  Document the process steps Train and create more setting experts
  20. 20. Case study examples on changeover loss reduction using SMED concept in our client’s process
  21. 21. Examples of Changeover reduction in our Client's Operations
  22. 22. Thank you for your Interest To Know more about those case studies ,pl mail to us mobile : +91 90259 33666 For Business and Life Excellence articles and case studies pl visit website :