TPM PRECISION CHANGEOVERS

Total Productive Maintenance

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Precision Changeovers



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• Define a changeover in your environment.

• When does changeover start?

• When does it end?

• What the impact on the process?

Changeover?



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The 4 Phase Analysis Process ~ Overview

PHASE

1CURRENT STATE Internals & Externals mixed together

2SPLIT PHASE Separate Internals from Externals

3CONVERSION PHASE Convert Internals to External & Streamline Internals

4

STREAMLINING PHASE Eliminate adjustments & streamline remaining Internals AND externals

PRODUCTA

PRODUCTA

PRODUCTA

PRODUCTA

PRODUCTB

PRODUCTB

PRODUCTB

PRODUCTB

PRODUCT CHANGE TIME

INTERNAL

INT.

INT. INT. INT.EXT. EXT.EXT.

INTERNAL

INT.EXT.

Organisational Improvements

Technical Improvements

Technical / Organisational Improvements

EXT.

EXT.

EXT.

EXT.



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Reduction in motion – Spaghetti diagram

BEFORE AFTER

PRODUCTA

PRODUCTA

PRODUCTA

PRODUCTA

PRODUCTB

PRODUCTB

PRODUCTB

PRODUCTB

PRODUCT CHANGE TIME

INTERNAL

INT.


INTERNAL

INT.EXT.




EXT.



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• Roles and Responsibilities– Operator– Maintenance Electrician– Time Keeper– Data Sheet Recorder– Activity Monitor (Spaghetti Diagram)– Improvement Team

Changeover Simulation



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Carry out a changeover!

Blue Circles to Red Diamonds

STEP 1:Analyse the Current process



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• Identify the start and end of the changeover• Observe the changeover (use video if possible)• Record ALL observations/ideas on post-it notes during changeover (One

fact per post it / be specific / readable / useful facts & phrases)• Record elements of operation and data on changeover analysis sheet




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Create the Changeover ChartChangeover

ElementTime

Observations

Internal

External

Streamlining

Savings

New Standard Process

New Time

Operation steps in sequence

Operation time for individual stepObservations / suggestions noted during changeover

Remove Vice

110 secs




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Step 1: Analyse the current process

Create the Changeover ChartChangeover

Element

Time

Observations

Internal

External

Streamlining

Savings


New Time

Operation steps in sequence

Operation time for individual stepObservations / suggestions noted during changeover

Remove Vice

30

110 secs

Raw material by M/C

MS

PRODUCTA

PRODUCTA

PRODUCTA

PRODUCTA

PRODUCTB

PRODUCTB

PRODUCTB

PRODUCTB

PRODUCT CHANGE TIME

INTERNAL

INT.


INTERNAL

INT.EXT.




EXT.



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STEP1:AnalysetheCurrentprocess



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Changeover Time

84

71

20

102030405060708090

Min

utes

Step 1 Current state

Target

Step 1: Set the Target



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Step2:Separateinternalfromexternal



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Step 2: Separate Internal toExternal Action Plan

• Get tools by machine onto shadow board• Contact electrician in advance• Have earth fitting pre fixed• Plate off/On at station• Setting Standards by line• Pre check Raw Materials• Materials at line



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Changeover Time84

71

112

0102030405060708090

Min

utes

Step 1 Current state Target

Progress at Step 2

Step 2



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Step 3: Convert Internal to External

• Discuss every step and every possible technical improvement that can be made at this point to improve and/or eliminate steps.

• Move any technical changes to external where possible.

• Record time saved.



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Step 3: Convert internal to external

Challenge normal thinking……… PRODUCTA

PRODUCTA

PRODUCTA

PRODUCTA

PRODUCTB

PRODUCTB

PRODUCTB

PRODUCTB

PRODUCT CHANGE TIME

INTERNAL

INT.


INTERNAL

INT.EXT.




EXT.



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Step 3: Convert Internal to ExternalUpdate the Changeover Chart & Action Plan

Changeover Element

Time

Observations

Internal

External

Streamlining

Savings


New Time

Convert internal to external, where possible, and indicate assessment has been made with a diagonal line



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Step 3 : Convert Internal to External

• Change tool with Heat resistant PPE to eliminate waiting for tool to cool.

• Place of cooling station at workstation.

• Preheat next tool and place online using PPE.



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Changeover Time

84

71

111.1 2

0102030405060708090

Min

utes

Step 1 Current state Target

Progress at Step 2

Step 2

Result



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Update the Changeover Chart & Action Plan

Step 4: Streamline & rationalise

Changeover Element

Time

Observations

Internal

External

Streamlining

Savings


New Time

Ideas / suggestions to make things faster and rationalise operations

Reduce number of bolts?

110 secs

Calculate savings made by streamlining actions

Move all remaining internal elements to ‘New StdProcess’ and calculate new time from any savings



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Functional Clamps

Step 4: Streamline & rationalise (internal)



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Step: Streamline & rationalise (internal)

One Turn Methods



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Step 4: Streamline & Rationalise (internal)

Parallel Operations

At bottlenecks use a team for the changeover bringing in operators from non bottleneck machines



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Step 4: Streamline & rationalise (external)

Organisation & Visualisation

(Materials ~ Tools ~ Equipment)



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Step 4: Streamline & Rationalise (external)

SOPs & Checklists

Prepared TPM Team

23/07/2002

Ref No S3-CC-001

Issue 1

Date

Clean all carriage location dowels and report if missing.

Remove any debris and wipe surface area of base plate

Equipment - Dry Cloth, Cleaning Solution, Gloves and Dustpan & Brushes

Wipe the stamping head clean of any contamination

Wipe grease and dirt from front and underside of dummy disc & fixture block

04

121109

0301

Remove any debris and wipe top plate and the Emergency Stop button

02

Wipe surface area of the stamping unit. Take care not to adjust the setting wheel

05

Clean and remove swarf from the vacuum tray and check for suction

06

Wipe left and right cylinders. Take care when cleaning around sensor wiring

07

Wipe clean all brass stops. Push brass block down to confirm its not sticking

08

Wipe central control valve block and take care not to move flow adjustors

10

Wipe conveyor track and trunking of any excess grease and dirt

Team Leader to safely isolate unit prior to clean & check

X 6

AL11 - A140 Changeover Procedure

Operator to immediately inform any problems found to Team Leader

End of Shift



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Step 4 : Streamline & rationalise

• Install plug and train ops to use

• Quick release clips

• Locating Pins

• Setting Blocks

• Training



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Step 4: Streamline & rationalise

PLAN• Install plug and train ops to use• Quick release clips• Locating Pins• Setting Blocks• Training



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DO• Install plug and train ops to use• Quick release clips• Locating Pins• Setting Blocks• Training



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V2


CHECK – NEW SOP



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ACT – RUN CHANGEOVER!



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V2


ACT – RUN REPEAT CHANGEOVER WITH

SECOND OP

Business

TPM PRECISION CHANGEOVERS