View
226
Download
2
Category
Preview:
Citation preview
www.newpotentialcbs.com Proprietary information of New Potential
Quick Changeover Examples (SMED)
AMF – Process Improvement Group 16 February 2017
Slide 2 Proprietary information of New Potential
Ø OBSERVE the process
Remember the Basics
Ø IDENTIFY steps that NEED to be done whilst stopped and what CAN be done whilst it’s running
Ø OPTIMISE – Shorten INT
Ø MOVE INT to EXT
Ø OPTIMISE – Shorten EXT
Slide 3 Proprietary information of New Potential
• Early 1970’s startup called Southwest Airlines posted loss of $1.6m.
• Forced to sell 1 of its planes within 24mths
Services – Southwest Airlines
The answer: Unload and load passengers faster than any other airline and get planes back in the air … “The 10 minute Turnaround” The following year SA posted its first profit and stayed black since
Slide 4 Proprietary information of New Potential
… ruthlessly applied the principles
Southwest – How did they do it?
Park at gate Land Take-
off Taxi Re
trieve
lug
gage
Alight Clean Reload/
Seating Checks
Push
back
Park at gate Land Take-
off Taxi
Retrie
ve
lugga
ge
Alight Clean Reload/ Seating Checks
Push
back
Identified ‘External’ steps …
Slide 5 Proprietary information of New Potential
• Moved INT to EXT • Looked for parallel work opportunities
Southwest – How did they do it?
Park at gate Land
Take-off
Taxi
Retrie
ve
lugga
ge
Alight
Clea
n Reload/ Seating
Chec
ks
Push
back
Slide 6 Proprietary information of New Potential
Before and after …
Southwest – How did they do it?
Park at gate Land
Take-off
Taxi
Retrie
ve
lugga
ge
Alight
Clea
n Reload/ Seating
Chec
ks
Push
back
Park at gate Land Take-
off Taxi
Retrie
ve
lugga
ge
Alight Clean Reload/ Seating Checks
Push
back
process time
• Reduction in turnaround (process lead time) • Reduced costs • Competitive edge
Slide 7 Proprietary information of New Potential
• Used same aircraft (versus 10 at competitors) Ø Interchangeability (aircraft and components) Ø Simplified mechanics training and skill set Ø Lower spares inventory Ø Same size/shape for gate access
• Point to Point Operation Ø Less congestion than at Hubs (slot availability and volatility) Ø Less impact of weather
• Don’t charge customers for bags
Applying the Principles
1. Single Minute Exchange of People
2. Single Minute Exchange of Aircraft
Slide 8 Proprietary information of New Potential
What are the obvious steps they made ‘EXTERNAL’
How Fast Can You Change a Tyre?
Slide 9 Proprietary information of New Potential
Manufacturing – Quick Changeover
• Die alignment – tolerances on dowels with chamfers • Automated coating process in cabinet whilst preparing machine • Moved inspection to ‘External’ • Standardized ‘warm-up’ process • Reduced the need to fetch documentation ‘Inside’ operation • Stopped continual tampering with dies – made them compliant
Slide 10 Proprietary information of New Potential
Same principles and questions need to be asked Involve process workers
Manufacturing/Assembly – Quick Changeover
Examples: • Indexed assembly carousels • Implement parallel activities • Quick release clamping, or boltless clamping methods • Snap-on hose connectors • Positive location methods (eliminate adjustments) • Multiple entry points to machine/assembly jigs • Etc.
Slide 11 Proprietary information of New Potential
• Less downtime • Less inventory (smaller batches) • Quicker turnaround (responsiveness) • Better delivery performance • Reduced costs • Easier for employees
Benefits
Slide 12 Proprietary information of New Potential
• SMED (Quick changeover) – improves productivity for a particular type of problem Other lean improvement techniques improve productivity, reduce costs and improve quality
Tips: • Involve process users – (video if possible) • Focus on the right problematic areas – not FOTM • Standardization – codify not tacit
• Don’t take away the examples as templates – take away the principles • Your application will be unique, but relevant
Summary and Health Warnings
Slide 13 Proprietary information of New Potential
Gavin Jones gavinjones@newpotentialcbs.com www.newpotentialcbs.com 07852 595 576
Recommended