Quick Changeover for Operators

The SMED System

Author: Productivity Press. Development Team,Shigeo Shingo

Publisher: SteinerBooks

ISBN: 9781563271250

Category: Business & Economics

Page: 77

View: 3647

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Changeover is the process of setting up a production line for a different process or product. Many plants take hours or even days to do a changeover - a major barrier to manufacturing flexibility. Quick Changeover for Operators, based on Shigeo Shingo's SMED system, teaches frontline employees the techniques and approaches that turn hours of changeover time into minutes, even seconds! Now the learning format in the Shopfloor Series makes these powerful techniques accessible to the whole workforce. SMED is short for "Single-Minute Exchange of Die." The "single" here means a single-digit number of minutes - less than ten. The SMED approach is simple and universal. It works in companies all over the world. Although it was first used in (and named for) manufacturing with dies, the basic principles of SMED have been used to reduce setup and turnaround time in all types of manufacturing, assembly, and even service industries, from process and packaging plants to airlines.

Kaizen for Quick Changeover

Going Beyond SMED

Author: Keisuke Arai,Kenichi Sekine

Publisher: Productivity Press

ISBN: 9781563273414

Category: Business & Economics

Page: 320

View: 1202

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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.

Quick Changeover Simplified

The Manager's Guide to Improving Profits with SMED

Author: Fletcher Birmingham,Jim Jelinek

Publisher: Productivity Press

ISBN: 9781563273490

Category: Business & Economics

Page: 128

View: 4594

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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.

Achieving Lean Changeover

Putting SMED to Work

Author: John R. Henry

Publisher: CRC Press

ISBN: 1466589213

Category: Business & Economics

Page: 205

View: 7387

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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.

OEE for Operators

Overall Equipment Effectiveness

Author: Productivity Press Development Team

Publisher: SteinerBooks

ISBN: 9781563272219

Category: Business & Economics

Page: 96

View: 5365

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Addressing those who track and improve the effectiveness of equipment, this text defines basic concepts and then provides a systematic explanation of how OEE should be applied to maximize a piece of equipment's productivity and recognize when its efficiency is being compromised.

New Manufacturing Challenge

Techniques for Continuous Improvement

Author: Kiyoshi Suzaki

Publisher: Simon and Schuster

ISBN: 0029320402

Category: Business & Economics

Page: 255

View: 417

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Identifies the most prominent forms of waste in factories, suggests how to combine and simplify operations, and provides practical examples

Focused Equipment Improvement for TPM Teams

Author: JapanInstituteofPlantMaintenance

Publisher: Routledge

ISBN: 1351447734

Category: Business & Economics

Page: 142

View: 1059

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As distinguished from autonomous maintenance, where the main goal is to restore basic conditions of cleanliness, lubrication, and proper fastening to prevent accelerated deterioration, FEI looks at specific losses or design weaknesses that everyone previously thought they just had to live with. Once your TPM operator teams are progressing with their daily autonomous maintenance activities, you will want to take the next advanced step in TPM training with this book. Key Features: a simple and powerful introduction to P-M Analysis hints for unraveling breakdown analysis numerous ideas for simplifying and shortening setups ideas for eliminating minor stoppages and speed losses basic concepts of building quality into processing real-life examples from a leading Japanese tool company Educate and empower all your workers to support your TPM improvement activities with

A Revolution in Manufacturing

The SMED System

Author: Shigeo Shingo

Publisher: Productivity Press

ISBN: 9780915299034

Category: Business & Economics

Page: 361

View: 5793

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"Dr. Shingo, inventor of the Single-Minute Exchange of Die (SMED) system for Toyota, shows you how to reduce your changeovers by an average of 98 percent! By applying Shingo's techniques, you'll see rapid improvements (lead time reduced from weeks to days, lower inventory and warehousing costs) that will improve quality, productivity, and profits." - product description.

Cellular Manufacturing

One-Piece Flow for Workteams

Author: ProductivityDevelopmentTeam

Publisher: Routledge

ISBN: 1351462016

Category: Business & Economics

Page: 86

View: 6592

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Cellular Manufacturing: One-Piece Flow for Workteams introduces production teams to basic cellular manufacturing and teamwork concepts and orients them for participating in the design of a new production cell. Use this book to get everyone on board to reduce lead time, work-in-process inventory, and other profit-draining wastes. Each chapter includes an overview and a summary to reinforce concepts, as well as reflection questions, which can be used to encourage group discussions. This volume is part of Productivity Press’ Shopfloor Series, which offers a simple, cost-effective approach for building basic knowledge about key manufacturing improvement topics

Quick Changeover for Operators

The Smed System

Author: Productivity Press,Shigeo Shingo,Productivity Development Team

Publisher: N.A

ISBN: 9781563271267

Category: Business & Economics

Page: 85

View: 6240

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SMED (Single Minute Exchange of Die) or quick changeover technique is the single most powerful tool for JIT production. Changeover is the process of setting up a production line for a different process or product. Many plants take hours or even days to do a changeover-a major barrier to manufacturing flexibility. This learning package, based on Shigeo Shingo's SMED System, begins the education process of teaching frontline employees the techniques and approaches that turn hours of changeover time into minutes, even seconds!

Poka-Yoke

Improving Product Quality by Preventing Defects

Author: Nikkan Kogyo Shimbun

Publisher: CRC Press

ISBN: 9780915299317

Category: Business & Economics

Page: 304

View: 4639

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If your goal is 100% zero defects, here is the book for you — a completely illustrated guide to poka-yoke (mistake-proofing) for supervisors and shop-floor workers. Many poka-yoke ideas come from line workers and are implemented with the help of engineering staff or tooling or machine specialists. The result is better product quality and greater participation by workers in efforts to improve your processes, your products, and your company as a whole. The first section of the book uses a simple, illustrated format to summarize many of the concepts and main features of poka-yoke. The second section shows 240 examples of poka-yoke improvements implemented in Japanese plants. The book: Organizes examples according to the broad issue or problem they address. Pinpoints how poka-yoke applies to specific devices, parts and products, categories of improvement methods, and processes. Provides sample improvement forms for you to sketch out your own ideas. Use Poka-yoke in study groups as a model for your improvement efforts. It may be your single most important step toward eliminating defects completely. (For an industrial engineering perspective on how source inspection and poka-yoke can work together to reduce defects to zero, see Shigeo Shingo's Zero Quality Control.)

Mistake-Proofing for Operators

The ZQC System

Author: Productivity Press Development Team,Productivity Press

Publisher: SteinerBooks

ISBN: 9781563271274

Category: Business & Economics

Page: 80

View: 3447

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The Zero Quality Control System (ZQC) is a mistake-proofing approach that prevents defects by monitoring processing conditions at the source and correcting errors that cause defects. Since it is human nature to make mistakes, ZQC does not blame people for errors, but instead finds ways to keep errors from becoming defects. In this breakthrough approach, mistake-proofing devices called poka-yoke are used to check and give feedback about each product or operation in the process, not just a sample. This book introduces operators and assembly workers to the basic methodology of ZQC in an easy-to-read format that covers all aspects of this important manufacturing improvement strategy. Mistake-Proofing for Operators includes the instructional features that are the signature of the Shopfloor Series. In this series Productivity Press has taken the lead in adult education by teaming with instructional designers to develop complete programs for frontline learning. The goal: to place powerful and proven improvement tools such as ZQC and mistake-proofing in the hands of your company's entire workforce. Winner of the 1990 Shingo Prize for Excellence in Manufacturing, Mistake-Proofing for Operators is based on Zero Quality Control: Source Inspection and the Poka-Yoke System by Shigeo Shingo

Total Productive Maintenance

Proven Strategies and Techniques to Keep Equipment Running at Maximum Efficiency

Author: Steve Borris

Publisher: McGraw Hill Professional

ISBN: 9780071589260

Category: Technology & Engineering

Page: 448

View: 7084

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Reduce or eliminate costly downtime Short on teory and long on practice, this book provides examples and case studies, designed to provide maintenance engineers and supervisors with a framework for operational strategies and day-to-day management and training techniques that will keep their equipment running at top efficiency.

Autonomous Maintenance for Operators

Author: Japan Institute Japan Institute of Plant Maintenance,Japan Institute of Plant

Publisher: N.A

ISBN: 9781138438736

Category:

Page: N.A

View: 1300

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TPM leads to soaring productivity when your operators are positively and energetically involved in the maintenance of their own equipment. Autonomous Maintenance for Operatorsteaches specific autonomous maintenance activities. For operators, supervisors, team leaders, and TPM coordinators, this book provides useful guidance and case study examples on autonomous maintenance. Activity boards, one-point lessons, photos, cartoons, and actual examples of implementation demonstrate the huge benefits of developing informed, motivated operators who take ownership of and improve their equipment. Shopfloor operators will learn: 4 skills they can develop to keep equipment running smoothly. how to inspect for problems as they clean equipment. ideas for containing debris that shortens equipment life. tips for effective lubrication management. how to use activity boards, meetings, and one-point lessons to promote TPM goals. This book assumes some familiarity with the steps of autonomous maintenance and focuses on specific autonomous maintenance activities.

Autonomous Maintenance in Seven Steps

Implementing TPM on the Shop Floor

Author: Fumio Gotoh,Masaji Tajiri

Publisher: Productivity Press

ISBN: 9781563272196

Category: Business & Economics

Page: 352

View: 5800

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Autonomous maintenance is an especially important pillar of Total Productive Maintenance (TPM) because it enlists the intelligence and skills of the people who are most familiar with factory machines-- equipment operators. Operators learn the maintenance skills they need to know through a seven-step autonomous maintenance program. Most companies in the West stop after implementing the first few steps and never realize the full benefits of autonomous maintenance. This book contains comprehensive coverage of all seven steps--not just the first three or four. It includes: An overview of autonomous maintenance features and checklists for step audits to certify team achievement at each AM step. TPM basics such as the six big losses, overall equipment effectiveness (OEE), causes of losses, and six major TPM activities. An implementation plan for TPM and five countermeasures for achieving zero breakdowns. Useful guidelines and case studies in applying AM to manual work such as assembly, inspection, and material handling. Integrates examples from Toyota, Asai Glass, Bridgestone, Hitachi, and other top companies. By treating machines as partners and taking responsibility for them, you get machines that you can rely on and help maintain an energized and responsive workplace. For companies that are serious about taking autonomous maintenance beyond mere cleaning programs, this is an essential sourcebook and implementation support.

Just-In-Time for Operators

Author: Productivity Press Development Team,

Publisher: N.A

ISBN: 9781138438705

Category:

Page: N.A

View: 4678

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Are you ready to implement a just-in-time (JIT) manufacturing program but need some help orienting employees to the power of JIT? Here is a concise and practical guide to introduce equipment operators, assembly workers, and other frontline employees to the basic concepts, techniques, and benefits of JIT practices. Like all Shop Floor Series books, Just-in-Time for Operators presents concepts and tools in simple and accessible language. The book includes ample illustrations and examples to explain basic JIT concepts and some of the changes people may encounter in a JIT implementation.Key definitionsElimination of process wasteLeveled production, kanban, and standard workU-shaped cells and autonomationJIT support techniquesThe JIT approach is simple and universal -- it works in companies all over the world. Educating employees ensures their full participation and allows them to share their experiences and ideas more effectively.

The OEE Primer

Understanding Overall Equipment Effectiveness, Reliability, and Maintainability

Author: D.H. Stamatis

Publisher: CRC Press

ISBN: 1439814082

Category: Business & Economics

Page: 502

View: 1551

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A valuable tool for establishing and maintaining system reliability, overall equipment effectiveness (OEE) has proven to be very effective in reducing unscheduled downtime for companies around the world. So much so that OEE is quickly becoming a requirement for improving quality and substantiating capacity in leading organizations, as well as a required area of study for the ISO/TS 16949. Breaking down the methodology from a historical perspective, The OEE Primer: Understanding Overall Equipment Effectiveness, Reliability, and Maintainability explores the overall effectiveness of machines and unveils novel methods that focus on design improvement—including hazard analysis, rate of change of failure (ROCOF) analysis, failure rate finite element analysis (FEA), and theory of inventive problem solving (TRIZ). It covers loss of effectiveness, new machinery, electrical maintenance issues, Weibull distribution, measurement techniques, and mechanical and electrical reliability. The book also: Discusses Reliability and Maintainability (R&M), not as tools to be used in specific tasks, rather as a discipline Covers the application of OEE as an overall improvement tool Assesses existing and new equipment from classical, reliability, and maintainability perspectives Includes a bonus CD with more than 100 pages of appendices and additional resources featuring statistical tables, outlines, case studies, guidelines, and standards Introducing the classical approach to improvement, this book provides an understanding of exactly what OEE is and how it can be best applied to address capacity issues. Highlighting mechanical and electrical opportunities throughout, the text includes many tables, forms, and examples that clearly illustrate and enhance the material presented.

Non-Stock Production

The Shingo System of Continuous Improvement

Author: Shigeo Shingo

Publisher: CRC Press

ISBN: 9780915299300

Category: Business & Economics

Page: 479

View: 4352

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Shingo, whose work at Toyota provided the foundation for JIT, teaches how to implement non-stock production in your JIT manufacturing operations. The culmination of his extensive writings on efficient production management and continuous improvement, this book is an essential companion volume to his other landmark books on key elements of JIT, including SMED and poka-yoke. It includes: Fundamental flaws in European and American production philosophies. Basic concepts for improving production systems. The "scientific thinking mechanism" -- a new approach to improvement. Implementing a production method in an age of authorized stock production. Development of production functions in the age of non-stock production. Significance of the different production systems.