This document discusses techniques for reducing changeover times between production runs including SMED (Single Minute Exchange of Die), quick changeovers, and optimizing lot sizes. It provides formulas for calculating economic lot size and total cost curves. Methods are presented for classifying, observing, recording, and analyzing changeover processes to identify ways to externalize setup steps, reduce internal changeover times, and implement principles like having tools organized on a trolley. Frequent recording and competitions are encouraged to continuously improve changeover performance.

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SMED
(or)
QUICK CHANGEOVER

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Factory Within A Warehouse

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Benefits Of Small Lot Production
Less manufacturing lead time
Quick delivery to the customer
Low risk of product obsolescence
Improved cash flow because of less inventory
Less space for storage

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Total Cost Curve
COST
LOT SIZE
Cost Of
Changeover
Cost Of Inventory
The Optimization Model
Economic Lot
Size

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FORMULA ONE

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How To Do A Quick Changeover
The Answer Lies Here
Process
Observation
Video Tape it if
possible

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CLASSIFYING SETUP OPERATIONS

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1. Record change-over
process and analyse
2. Internal change-over
must be externalised
GOAL: 50%
3. Internal change-over
time has to be reduced
Change-over principles
A B C
A B C
B C
External before Internal External after
External before Internal External after
External before Internal External after
The 3 Step Method
A C

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SMED Trolley
No Search For
Tools

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3 More Golden Rules
Do not mind deploying additional people to
do a changeover
Record changeover every time and create a
visual display
Run Changeover competitions frequently

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Thank You