NG BB 45 Quick Change Over
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This document discusses quick changeover techniques to improve process efficiency. It begins by outlining an 8-step process improvement methodology. It then defines changeover times and differentiates between traditional and continuous process improvement thinking regarding changeovers. The document explains that quick changeovers can decrease downtime and waste, allowing for increased flexibility through smaller batch sizes. It provides steps to identify internal and external changeover activities, convert internal activities to external to reduce downtime, and further reduce all remaining activities through techniques like parallel operations and automation.
NG BB 45 Quick Change Over
- 1. UNCLASSIFIED / FOUO National Guard Black Belt Training Module 45 Quick Changeover UNCLASSIFIED / FOUO
- 2. UNCLASSIFIED / FOUO CPI 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. 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. 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. UNCLASSIFIED / FOUO Why Quick Changeover? Shorter Changeover Times More Frequent Changeovers Smaller Batch Sizes Shorter Lead Times Increased Combat Capability! UNCLASSIFIED / FOUO 5
- 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. UNCLASSIFIED / FOUO Changeover 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. 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. 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. 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. UNCLASSIFIED / FOUO Improvement Steps 1. Identify activities and document the process. 2. Separate Internal from External activity 3. Convert Internal to External UNCLASSIFIED / FOUO 11
- 12. UNCLASSIFIED / FOUO Converting 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. 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. 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. UNCLASSIFIED / FOUO Pit Stop Photo Team with Pre-assigned Tasks Placement Clearly Defined Quick Connect & Tools Properly Positioned Prior Disconnect Devices to Arrival UNCLASSIFIED / FOUO 15
- 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. UNCLASSIFIED / FOUO What other comments or questions do you have? UNCLASSIFIED / FOUO 17