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National GuardBlack Belt Training
National GuardBlack Belt Training
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Module 45
Quick Changeover
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CPI Roadmap – Improve
Note: Activities and tools vary by project. Lists provided here are not necessarily all-inclusive.
TOOLS
•Brainstorming
•Replenishment Pull/Kanban
•Stocking Strategy
•Process Flow Improvement
•Process Balancing
•Standard Work
•Quick Change Over
•Design of Experiments (DOE)
•Solution Selection Matrix
• ‘To-Be’ Process Mapping
•Poka-Yoke
•6S Visual Mgt
•RIE
ACTIVITIES• Develop Potential Solutions
• Develop Evaluation Criteria
• Select Best Solutions
• Develop Future State Process Map(s)
• Develop Pilot Plan
• Pilot Solution
• Develop Full Scale Action/
Implementation Plan
• Complete Improve Gate
1.Validate the
Problem
4. Determine Root
Cause
3. Set Improvement
Targets
5. Develop Counter-
Measures
6. See Counter-MeasuresThrough
2. IdentifyPerformance
Gaps
7. Confirm Results
& Process
8. StandardizeSuccessfulProcesses
Define Measure Analyze ControlImprove
8-STEP PROCESS
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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!
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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) IncreasesFlexibility
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Why Quick Changeover?
Shorter Changeover Times
More Frequent Changeovers
Smaller Batch Sizes
Shorter Lead Times
Increased Combat Capability!
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Internal vs. External
The first task is to recognize that there
are two essentially different components
of any changeover, Internal Activities
and External Activities.
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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
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Improvement Steps
1. Identify changeover activities and document the process (time each step).
2. Separate Internal activity from External activity
External ExternalInternal
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Internal vs. External Quiz
Possible CT Scan Changeover Steps:1. Machine is turned off as scan ends
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
Which are
Internal &
Which should
be External?
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Internal vs. External Quiz
Possible CT Scan Changeover Steps:1. Machine is turned off as scan ends
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
Internal
External
Adapted from “A Lean Guide to
Transforming Healthcare”, Zidel, 2006
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Improvement Steps
1. Identify activities and document the process.
2. Separate Internal from External activity
3. Convert Internal to External
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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
Converting Internal to External
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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.
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Perform Parallel Operations
Improve Clamping Mechanisms
One turn clamps
One motion methods
Eliminate all adjustments
Numerical Settings vs. “Feel”
Automate activities where appropriate
Reduce All Remaining Activities
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Pit Stop Photo
Team with Pre-assigned Tasks Placement Clearly
Defined
Quick Connect &
Disconnect Devices
Tools Properly Positioned Prior
to Arrival
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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
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What other comments or questions
do you have?
