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Lean Champion Black Belt 9 - Develop Quick Changeovers (PowerPoint PPT Slide Deck)
PowerPoint (PPT) 71 Slides
LEAN SIX SIGMA BLACK BELT PPT DESCRIPTION
The Lean Champion Black Belt Series are designed and developed specifically for Manager and above roles. These series are at the highest standard among the enterprise series. When a person completes all the 15 modules he / she can be awarded a "Lean Champion" certificate which is equivalent to a Black Belt and can lead groups of team in successfully developing strategies and implementation of various Lean principles.
The 15 modules are:
1. Intro 2 Lean Manufacturing – 108 slides
2. Map a Value Stream – 112 slides
3. Hoshin Kanri Policy Deployment – 50 slides
4. Develop a Lean Culture – 46 slides
5. Develop a Balanced Scorecard – 70 slides
6. Develop a Continuous Improvement System – 72
7. Optimize Product Cost – 67 slides
8. Manage 5S – 48 slides
9. Develop Quick Changeovers – 71 slides
10. Develop JIT – 47 slides
11. Implement a TPM – 58 slides
12. Determine & Establish Information Collection Requirements – 96 slides
13. Determine and Improve Process Capability – 60 slides
14. Apply Six Sigma to Process Control & Improvement – 79 slides
15. Process Optimization using Six Sigma – 94 slides
The 9th Module "Develop Quick Changeovers" covers the following topics:
• Define Changeovers and understanding SMED concept
• 4 Steps to set-up reduction
1. Improving production scheduling.
2. Separating Internal and External Setup
3. Converting Internal to External Setup
4. Streamlining All Aspects of the Setup Operation
• Workplace Project
• Check-lists for set-up reduction
You can also buy all the 15 modules at a 25% discounted as a bundled product.
Also add other presentations depending on your requirements, such as Kanban Implementation, Heijunka Implementation, Site Review Check List, Lean Assessment, Lean Leader and Lean Culture Surveys and BSC Assessment.
The module delves into benchmarking changeovers, providing insights on achieving world-class standards. It includes real-world case studies and practical tools to streamline setup operations and reduce downtime.
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MARCUS OVERVIEW
This synopsis was written by Marcus [?] based on the analysis of the full 71-slide presentation.
Executive Summary
The Lean Champion Black Belt Module 9 - Develop Quick Changeovers presentation focuses on optimizing changeover processes through the Single Minute Exchange of Die (SMED) methodology. This training, crafted by a seasoned Lean Six Sigma Master Black Belt, provides actionable insights for reducing setup times, enhancing production efficiency, and minimizing waste. Participants will learn to implement effective strategies for quick changeovers, ultimately leading to significant cost savings and improved operational flexibility.
Who This Is For and When to Use
• Operations Managers seeking to enhance production efficiency
• Lean Practitioners focused on waste reduction
• Manufacturing Engineers involved in process optimization
• Continuous Improvement Teams aiming to implement SMED techniques
Best-fit moments to use this deck:
• During Lean training sessions to introduce changeover optimization
• In workshops focused on process improvement initiatives
• When addressing specific challenges related to lengthy changeovers
Learning Objectives
• Define changeovers and the SMED concept
• Build a structured approach to setup reduction
• Establish methods for separating internal and external setup tasks
• Identify opportunities for streamlining setup operations
• Implement a checklist for effective setup reduction
• Analyze case studies to understand real-world applications of quick changeovers
Table of Contents
• Introduction to Changeovers (page 3)
• Understanding SMED (page 5)
• Importance of Setup Reduction (page 7)
• Steps to Reduce Changeover Time (page 10)
• Case Studies on Changeover Efficiency (page 15)
• Setup Reduction Goals (page 20)
• Practical Applications and Tools (page 25)
• Workplace Project Guidelines (page 30)
• Changeover Standards Development (page 35)
• Set-Up Reduction Checklist (page 40)
Primary Topics Covered
• Changeover Definition - The time taken between the last part of one production run and the first good part of the next run, crucial for measuring efficiency.
• SMED Overview - A methodology aimed at reducing changeover times to under ten minutes, enhancing production flexibility.
• Setup Reduction Steps - A four-step process including improving scheduling, separating internal and external setups, converting internal tasks to external, and streamlining operations.
• Case Studies - Real-world examples demonstrating the financial benefits of effective changeover strategies, including significant cost savings.
• Setup Reduction Goals - Establishing a target of 50% reduction in setup times, with a long-term goal of eliminating setup requirements entirely.
• Practical Tools and Techniques - Implementation of mobile changeover trolleys, kanban systems, and mistake-proofing methods to enhance efficiency.
Deliverables, Templates, and Tools
• Changeover observation forms for documenting current processes
• Setup combination worksheets for standardizing procedures
• Improvement Opportunity Sheets for tracking progress
• Checklist for evaluating setup reduction initiatives
• Project plan templates for implementing changeover strategies
• Standard operating procedures for changeover processes
Slide Highlights
• Visual representation of the SMED process and its benefits
• Case study results showcasing dramatic reductions in changeover times
• Flowcharts illustrating the steps to effective setup reduction
• Before-and-after comparisons of changeover processes
• Key metrics for measuring changeover efficiency
Potential Workshop Agenda
Introduction to Changeovers (30 minutes)
• Overview of changeover definitions and impact on production
• Discussion on the importance of reducing setup times
SMED Techniques and Applications (60 minutes)
• Detailed explanation of SMED principles
• Group activity to identify internal vs. external setup tasks
Case Study Analysis (45 minutes)
• Review of successful changeover implementations
• Discussion on lessons learned and best practices
Action Planning Session (60 minutes)
• Develop individual action plans for implementing quick changeovers
• Share plans with peers for feedback and refinement
Customization Guidance
• Tailor the checklist to reflect specific operational contexts and equipment
• Adjust case studies to align with industry-specific challenges
• Incorporate company-specific terminology and metrics into training materials
Secondary Topics Covered
• Lean manufacturing principles and their relationship to setup reduction
• Waste identification and elimination strategies
• Ergonomics and safety considerations during changeovers
• Continuous improvement methodologies in manufacturing
FAQ
What is the SMED methodology?
SMED stands for Single Minute Exchange of Die, a system designed to reduce changeover times to under ten minutes by optimizing setup processes.
How can I implement quick changeovers in my facility?
Start by analyzing current changeover procedures, separating internal and external tasks, and applying the 4 steps outlined in the training module.
What are the expected outcomes of reducing setup times?
Reducing setup times can lead to increased production flexibility, lower inventory levels, and significant cost savings.
Can you provide examples of successful case studies?
Yes, case studies include Allied Tube, which saved millions by reducing changeover times, and Kreisler Manufacturing, which improved on-time deliveries significantly.
What tools are recommended for tracking changeover improvements?
Use changeover observation forms, improvement opportunity sheets, and standard work procedures to document and track progress.
How often should changeover processes be reviewed?
Regular reviews should occur as part of continuous improvement initiatives, ideally quarterly or after significant operational changes.
What role does employee training play in successful changeovers?
Training is critical for ensuring that employees understand and can effectively implement quick changeover techniques.
What metrics should be monitored post-implementation?
Monitor changeover times, production uptime, and inventory levels to assess the impact of implemented changes.
Glossary
• Changeover - The process of transitioning from one production run to another.
• SMED - A methodology aimed at reducing changeover times to enhance efficiency.
• Internal Setup - Tasks that can only be performed when equipment is not running.
• External Setup - Tasks that can be completed while the equipment is operational.
• Kaizen - A continuous improvement approach focusing on incremental changes.
• Lean Manufacturing - A production practice that considers the expenditure of resources in any aspect other than the direct creation of value for the end customer as wasteful.
• Mistake Proofing - Techniques designed to prevent errors in manufacturing processes.
• Kanban - A scheduling system for lean and just-in-time manufacturing.
• Takt Time - The maximum allowable time to produce a product to meet customer demand.
• 5S - A methodology for organizing and managing the workspace efficiently.
• Point of Use Storage (POUS) - A storage method that places tools and materials close to where they are needed.
• Continuous Improvement - Ongoing efforts to improve products, services, or processes.
• Setup Reduction Checklist - A tool used to evaluate and guide the setup reduction process.
• Workplace Project - A practical application of learned concepts in a real-world setting.
• Standard Operating Procedure (SOP) - A document that outlines the steps to perform a task or process.
• Changeover Master Plan - A strategic plan for reducing changeover times across operations.
• Bottleneck - A point of congestion in a production system that limits throughput.
• Waste - Any activity that does not add value to the product or service.
• Operational Excellence - An organizational philosophy that seeks to improve the efficiency and effectiveness of operations.
Source: Best Practices in Lean Six Sigma Black Belt, Setup Reduction PowerPoint Slides: Lean Champion Black Belt 9 - Develop Quick Changeovers PowerPoint (PPT) Presentation Slide Deck, OpEx Academy NZ
ABOUT THE AUTHOR
Vishnu Rayapeddi is an experienced management consultant and trainer specializing in implementing continuous process improvements. Vishnu is a pioneer in Lean Management which combines the power of Lean Thinking, TOC, Six Sigma, TQM, TWI, Balanced Scorecard, cGMP and other best-class methodologies such as, DMAIC, Value Stream Mapping, Root Cause Analysis, 5S, Quick Changeovers, Quality and ... [read more]
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