A Quick Start Guide for Setup and Changeover Reduction for Managers Quick Changeover Simplified: The Manager's Guide to Improving Profits with SMED, by Fletcher Birmingham and Jim Jelinek, is for companies that must implement a quick setup and changeover program, but aren't sure how to start. The authors walk you through the process of implementing a mini setup reduction program with some quick changeover tools and concepts that won't overwhelm you. When you start seeing the results and you're ready to implement a full-scale program, they'll take you through an eight-step process that's easy to understand. This compelling book is: A quick start guide that is concise and easy read. Written for those who understand the benefits of SMED but don't know how to start. Designed so that you can read it when you have only a few minutes to spare. Distinctive in that all the examples, including the ROI statistics, are real --companies have successfully used all the strategies and tools discussed. After you've read this book, learned the basics, and have successfully implemented a quick setup and changeover program, you'll see the results in shorter downtime and increased profits for your organization.

Shifting from external to internal set-up steps and optimizing your set-up procedure is only the first step in achieving world-class performance. What‘s most important is what comes next, cutting down internal set-up times and achieving changeovers that last only a few minutes.Quick Changeover Concepts Applied: Dramatically Reduce Set-Up Time and I

Defined as the total process of converting a line or process from one product to another, changeover will not only help your organization improve quality and flexibility, but it will save thousands and sometimes even tens of thousands of dollars per hour. Achieving Lean Changeover: Putting SMED to Work is about the practical implementation of the single minute exchange of die (SMED) philosophy developed by Shigeo Shingo at Toyota. Although the book is principally about changeover of manufacturing, packaging, and assembly processes, the general concepts and examples are also applicable in lighter industries that require turnover of processes including airlines, hospitals, operating rooms, and food service. Filled with practical examples, the book shares proven methods that can help you convert changeover downtime to productive uptime. It explains why reducing changeover time is important financially and provides a structured methodology to help you identify and implement improvement opportunities. The author addresses both the machinery issues with changeover/ SMED and the associated operational issues such as costs, waiting times, material movement, documentation, and product/component design. He also devotes a chapter to discussing, in detail, how to calculate the cost of changeover downtime, an area that remains a mystery to many. Taking a holistic approach to changeover, the text includes a chapter devoted to organizing changeover improvements, keeping them on track, and developing and implementing a formal changeover reduction program. Presenting time-tested methods and practical examples from a variety of industries, it offers you the opportunity to reduce changeover time and cost and provide your organization with the flexibility needed to better satisfy your customers in three important dimensions: product variety, responsiveness, and price.

Changeovers in 3 minutes or less! Picking up where Dr. Shingo's Single Minute Exchange of Die left off, this book streamlines the process even further to reduce changeover time, while simultaneously cutting staffing requirements in half. To instruct on how to achieve quick changeover in virtually any type of production environment, the book includes— A succinct eight-step process for setup improvement Nine basic principles for eliminating changeover waste The book begins by outlining the tactical principles for improving the three phases of the changeover procedure. Next it demonstrates how to improve changeover on a processing line. All of the ideas presented are based on kaizen improvements, which require very little, if any, expenditure. Process razing and the implementation of one-piece flow are also examined as means to eliminate wasteful transportation and searching.

Winner of a Shingo Research and Professional Publication Award Lean Production Simplified, Second Edition is a plain language guide to the lean production system written for the practitioner by a practitioner. It delivers a comprehensive insider's view of lean manufacturing. The author helps the reader to grasp the system as a whole and the factors that animate it by organizing the book around an image of a house of lean production. Highlights include: A comprehensive view of Toyota1s lean manufacturing system A look at the origins and underlying principles of lean Identifying the goals of lean production Practical problem solving for lean production Activities that support involvement - Kaizen circles, suggestion systems, and problem solving This second edition has been updated with expanded information on the Lean Improvement Process; Production Physics and Little's Law - the fundamental equation for both manufacturing and service industries (cycle time = work in process/throughput); Value Stream Thinking - combining processes required to bring the product or service to the customer; Hoshin Planning -- using the Planning and Execution Tree diagram and Problem Solving -- including the "Five Why" method and how to use it. Lean Production Simplified, Second Edition covers each of the components of lean within the context of the entire lean production system. The author's straightforward common sense approach makes this book an easily accessible on-the-floor resource for every operator.

When it comes to managing setup reduction within your organization, having the right guide to communicate and train employees in the concept is paramount. Enna's SMED Quick Changeover Facilitator Guide is designed with the shop floor in mind, and to allow for the performance of the workshop in-house. For this to take place, internal trainers require a practical and information rich guide to maximize their efforts. Enna's SMED Quick Changeover Guide provides you with this knowledge.

ReducedEffort® Changeover: The Lean Way to Quickly Reduce Changeover Downtime provides a step-by-step guide for conducting a Kaizen event that empowers the people who do the work to improve how that work is done. Packed with tips, tools, and examples, this practical guide begins with a clear description of the Lean principles underlying the ReducedEffort Changeover system. In addition, it explains how and why reducing the effort always reduces the time of converting a machine, line, or process from one product to another. In this book, you’ll find everything you need to quickly and dramatically reduce the effort and time of any process using the ReducedEffort method. This is not another book about how to do SMED. Like SMED, ReducedEffort Changeover (REC) does reduce changeover time, but REC is not SMED. SMED, Single Minute (or digit) Exchange of Dies, developed by Dr. Shigeo Shingo, has been the process used for many years by countless manufacturing plants to reduce changeover time. The SMED process was used in Toyota to reduce the changeover of a 1,000-ton stamping press from four hours to three minutes. As a Lean-based process, the REC system focuses on reducing the labor, not the time, involved in changing over a machine to work on a different product. With REC, there are no Standard Operation Combination Sheets to fill out and no Problem Identification Sheets to complete, and it does not require the arduous chore of timing every task, as SMED does. Very little capital investment is required with REC. Unlike SMED, it does not require management-approved funding to achieve substantial results. Because REC is not capital-driven, management does not need to drive the process. The operators will drive the process because it reduces their labor. One of the biggest advantages of REC over SMED is that operators will readily accept the process, and more important, they will want to sustain it. The reason for this is quite simple and will become evident when the REC process is defined. REC takes SMED to a new level that is easier and faster both to implement and to deliver sustainable results.