Kaizen for Quick Changeover: Going Beyond SMED

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CRC Press, Sep 1, 1992 - Business & Economics - 320 pages
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Changeovers in 3 minutes or less! That is the result of the process described in this book. Picking up where Dr. Shingo's Single Minute Exchange of Die left off, it streamlines the process even further to reduce changeover time and cut staffing requirements in half simultaneously!

The book describes how to achieve quick changeover in virtually any type of production environment with:

  • A succinct 8-step process for setup improvement.
  • 9 basic principles for eliminating changeover waste.

The book first outlines the tactical principles for improving the three phases of the changeover procedure. Next you'll learn how to improve changeover on a processing line. All of the ideas presented are based on kaizen improvements that require very little, if any, expenditure. Process razing and the implementation of one-piece flow are also examined as means for eliminating wasteful transportation and searching.

 

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Contents

Figure 11 Development of Improvements Toward Zero Changeover
4
Figure 17 Rotary System for Auto Changeover
11
Steps Toward Zero Changeover
13
Table 23 Press Operation Analysis Chart
18
Figure 24 Use of Block Gauges for Crank Standard Setting
24
A Formula for Achieving Zero Changeover
29
Figure 31 The Vertical Pivot Is the Standard
30
Figure 33 Railequipped Changeover Cart
34
Table 71 Sample Changeover Time Data
153
Figure 73 Combined Chute
160
Single Changeover in the Steel Forging Industry
163
Figure 82 Changeover Steps Before a and After b Improvement
166
Figure 86 Reduction of Changeover Time via Use of
172
Zero Changeover for Transfer Machines
175
Figure 91 Processing Defect Rate Oct 81 to Dec 84
178
Figure 94 Changeover Data from Various Processes 18283
185

Figure 35 Basic Approach for Replacement Items
41
Figure 312 Boltless Fastener Using Wedge Pins
47
Figure 316 Oneshot Die with Guideposts
54
Figure 322 Block Gauges and Other Methods for Positioning Devices
60
Processing Line Changeover Improvement Approaches
65
Figure 41 Large Press Line
68
Figure 45 Improved Conveyor Chute with Adjustable Angles
74
Figure 415 TwoHanded Use of Die Conveyance Table
80
Figure 422 Line with One Operator per Press
86
Table 43 WasteElimination Chart for Changeover Improvement
93
Making Inexpensive Improvements to Reduce Staffing Needs
101
Figure 51 Processing Line with Prechangeover Section
102
Figure 53 Robotequipped Press Line
103
Figure 59 Equipment Layout at Company As Press Factory
109
Figure 510 Test Line
116
Steps for Improving New Processing Lines
121
Figure 61 PQ Analysis Chart
123
Table 62 Time Measurement Chart for Rotor Assembly Line
129
Table 63 Processspecific WasteElimination Chart Company C
135
Figure 610 Assembly Process Chart
142
Improvement Case Studies
149
Figure 97 New Changeover Operation Instructions 18889
192
Figure 99 Universal Fixture for Intermediate Plate
198
Changeover Improvement Steps for the Process Industry
201
Figure 102 The Iceberg of Inventory Waste
205
Figure 103 Filling Line at Company B
209
Zero Changeover for PCB AutoInserters
219
Table 111 Changeover Operation Analysis
222
Zero Changeover for a Sheet Metal Factory
235
Table 121 Sheet Metal Processing Line Improvement
236
Zero Changeover for PlasticMolding Machines
245
Table 131 Color Change Times Before Improvement
247
Figure 132 Transverse Slide Method for Simultaneous Removal
253
Figure 135 Cassettetype Die Structure
259
Zero Changeover for DieCast Machines
261
Figure 144 Improvement in Changeover Time on 650Ton
265
Figure 148 Die Standardization
271
Zero Changeover for Assembly Lines
273
Figure 153 Line Integration of Sample Production
277
About the Authors
283
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