How to reduce changeover loss

How to reduce
“Changeover time loss”
and improve plant utilization

www.winningmindssolutions.com
• 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…

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.

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

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

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

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!

Traditional vs SMED based
Changeover
Traditional changeover
SMED based changeover
Say 20 min per Tyre
Say 20 sec for four Tyre

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

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

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

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

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

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

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

Improve External Elements
 Housekeeping-Location for all items
Visual Identification for all items
Colour Coding
Standard set up process
Checklist for each die setting

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.

Look for opportunities in Internal Elements..

Document and standardize ..
 Create Checklist for each die change
 Document the process steps
Train and create more setting experts

Case study examples
on changeover loss reduction using SMED concept
in our client’s process

Examples of Changeover reduction in our Client's Operations

Thank you for your Interest
To Know more about those case studies ,pl mail to us
ganesh@winningmindssolutions.com
mobile : +91 90259 33666
For Business and Life Excellence articles and case studies
pl visit website : www.winningmindssolutions.com

How to reduce changeover loss

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