Quick Changeover Simplified


Book Description

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


Book Description

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.




Kaizen for Quick Changeover


Book Description

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.




Lean Production Simplified


Book Description

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.




Lean Kaizen


Book Description

To compete successfully in today’s economy, organizations need to be as good as or better than their global competitors. This goes not only for quality, but also for costs and cycle times (lead time, processing time, delivery time, set-up time, response time, etc.). Lean addresses these needs in its emphasis on teamwork, continuous training and learning, produce to demand (“pull”), mass customization and batch size reduction, cellular flow, quick changeover, and total productive maintenance. Originally applied in manufacturing settings, lean has now migrated to non-shop floor activities: in business support functions, such as sales, customer service, accounting, human resources, engineering, purchasing; within manufacturing firms; and also in purely service areas like finance, government, and healthcare. The intended audience for this book is any quality or operational professional who wants to start their lean journey or enhance their career opportunities. After introducing the concepts of lean and kaizen, various building blocks of a lean enterprise are described. After reading this book, any reader will have a foundation of what is understood today as "lean." All the examples of kaizens presented in the book are from the authors' experience associated with real lean transformations. In addition, the forms, figures, and checklists included as part of this book and also on the accompanying CD-ROM can be customized and used in the readers’ own lean journey when they perform kaizens. COMMENTS FROM OTHER CUSTOMERS Average Customer Rating: (4 of 5 based on 1 review) "This book gives a great introduction to kaizen, along with a sensible "how to" and several case studies across various industries, including for non-manufacturing applications. It also gives a good introduction to Lean in general, and it places enough emphasis on the "human side" of implementing Lean so that the reader walks away with an understanding that the Lean tools may be fairly simple but the implementation of them requires special attention to human nature and the associated challenges. It is easy to read and comprehend. Plenty of pictures and samples are provided. This could easily be used as a training tool for employees who will be serving on kaizen teams." A reader in Bradenton, Florida




Quick Changeover Concepts Applied


Book Description

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




20 Keys to Workplace Improvement


Book Description

20 Keys has helped many manufacturing companies integrate the top manufacturing improvement methods into a coordinated system for drastic and continual improvement in involvement, quality, and productivity. This program provides the strategies necessary to achieve ambitious goals through a five-level scoring system. The revised edition is improved with upgraded criteria for the five-level scoring system to guide your company to world-class status. New material and updated layout make implementation even easier. Two valuable case studies demonstrate effective use by both a Japanese company and an American manufacturer.




The Product Wheel Handbook


Book Description

The Product Wheel (PW) design process has practical methods for finding the optimum sequence, minimizing changeover costs, and freeing up useful capacity. So much so, that the DuPont Company and Exxon Mobil are just a few companies that have used the product wheel concept to achieve and sustain a competitive advantage.Breaking down a fairly comple




Lean Office and Service Simplified


Book Description

Winner of a 2012 Shingo Research and Professional Publication AwardDemystifying the application of Lean methods, Lean Office and Service Simplified: The Definitive How-To Guide goes beyond the basic tools to detail the key concepts of Lean as they apply to office and service environments. It begins by discussing value stream management, followed by




Applying Lean Six Sigma in the Pharmaceutical Industry


Book Description

Bikash Chatterjee emphasizes the criticality of applying the principles of Lean and Six Sigma within the paradigm of the drug development process. His guide to operational excellence in the pharmaceutical and biotech industries is a focused summary of the application of Lean Six Sigma theory to the regulated life sciences. From molecule discovery to the application of PAT Applying Lean Six Sigma in the Pharmaceutical Industry will highlight the importance of framing these initiatives within the key deliverables of drug development manufacturing and quality. Challenging conventional wisdom the author offers a quality and efficiency perspective as a foundation for the principles of Quality by Design, PAT and the new philosophies underlying Process Validation. Each chapter includes discussion around the considerations for applying Lean manufacturing and Six Sigma principles and their tools, culminating in a case study to illustrate the application. The book is organized to reflect the major work centers involved in the drug development lifecycle. Each chapter is stand-alone but together they illustrate the necessary synergy between Lean, Six Sigma and compliance sensibilities required to be successful in the pharmaceutical industry. These design, manufacturing and management techniques are not without their challenges. Bikash Chatterjee's book offers the roadmap for an industry that is struggling to reinvent many of its development and business processes.