Download or read book Achieving Lean Changeover written by John Henry and published by . This book was released on 2012 with total page 205 pages. Available in PDF, EPUB and Kindle. Book excerpt: 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.

Download or read book Achieving Lean Changeover Coursebook written by John Henry and published by CreateSpace. This book was released on 2014-09-14 with total page 168 pages. Available in PDF, EPUB and Kindle. Book excerpt: This is the Powerpoint slide deck used with John Henry's Achieving Lean Changeover: Putting SMED to Work workshop. Normally presented in your facility. It is a useful companion to the book Achieving Lean Changeover: Putting SMED to Work from Productivity Press.

Download or read book Achieving Lean Changeover written by John R. Henry and published by CRC Press. This book was released on 2017-07-27 with total page 205 pages. Available in PDF, EPUB and Kindle. Book excerpt: 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 si

Download or read book ReducedEffort Changeover written by Ron Heiskell and published by CRC Press. This book was released on 2020-03-09 with total page 213 pages. Available in PDF, EPUB and Kindle. Book excerpt: 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.

Download or read book The Quick Changeover Playbook written by Chris A. Ortiz and published by CRC Press. This book was released on 2016-03-02 with total page 80 pages. Available in PDF, EPUB and Kindle. Book excerpt: This book covers the basics of setup reduction and quick changeover and data collection. It outlines the first pass of waste reduction through the implementation of the visual workplace and layout improvements. The book covers two quick changeover concepts: intermediate tooling and one-turn methods.

Download or read book Handbook of Research on Managerial Strategies for Achieving Optimal Performance in Industrial Processes written by Alor-Hernández, Giner and published by IGI Global. This book was released on 2016-05-03 with total page 674 pages. Available in PDF, EPUB and Kindle. Book excerpt: Competitive advantage is a key factor to the success of any business in modern society. To achieve this goal, effective strategies for process improvement must be researched and implemented into an organization. The Handbook of Research on Managerial Strategies for Achieving Optimal Performance in Industrial Processes examines optimization techniques for improved business operations and procedures in the industrial sector. Highlighting management techniques, innovative approaches, and technological tools, this publication is an essential reference source for professionals, researchers, consultants, upper-level students, and academicians interested in the advancement of knowledge in industrial communities.

Download or read book The Quick Changeover Playbook written by Chris A. Ortiz and published by . This book was released on 2019-10-02 with total page 74 pages. Available in PDF, EPUB and Kindle. Book excerpt: This book covers the basics of setup reduction and quick changeover and data collection. It outlines the first pass of waste reduction through the implementation of the visual workplace and layout improvements. The book covers two quick changeover concepts: intermediate tooling and one-turn methods.

Download or read book The Lean Book of Lean written by John Earley and published by John Wiley & Sons. This book was released on 2016-04-04 with total page 272 pages. Available in PDF, EPUB and Kindle. Book excerpt: An essential guide to bringing lean to your business and your life The Lean Book of Leanprovides a succinct overview of the concepts of Lean, explains them in everyday terms, and shows how the general principles can be applied in any business or personal situation. Disengaging the concept of Lean from any particular industry or sector, this book brings Lean out of the factory to help you apply it anywhere, anytime. You'll learn the major points and ideas along with practical tips and hints, and find additional insight in the illustrative examples. Lean is all about achieving the desired outcome with the minimum amount of fuss and effort, and this book practises what it preaches — concise enough to be read in a couple of sittings, it nonetheless delivers a wealth of information distilled into the essential bits you need to know. The Lean Book of Lean discards unnecessary specialisation and minute detail, and gets to the point quickly, so you can get started right away. Understand the basic principles of lean Recognise lean behaviours that come naturally Study examples of lean practices, policies, behaviours, and operations Apply lean concepts to both your business and personal life Lean is about being agile, efficient, responsive, productive, and smart. It applies to any and every aspect of life, from the factory floor to your morning routine. The Lean Book of Lean is the quick, smart guide to employing lean principles every day, so you can start doing more with less.

Download or read book ReducedEffort Changeover written by Ron Heiskell and published by Productivity Press. This book was released on 2020 with total page 174 pages. Available in PDF, EPUB and Kindle. Book excerpt: ReducedEffort(R) 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.

Download or read book ReducedEffort Changeover written by Ron Heiskell and published by . This book was released on 2018-06-06 with total page 144 pages. Available in PDF, EPUB and Kindle. Book excerpt: "We worked with Ron to implement the ReducedEffort(r) process and saw a 30% output improvement after just three days. The real bonus came with the unleashing of employee engagement."- Nick Wilson, President of Morrison Container Handling Solutions; Past Chairman of Packaging Machinery Manufacturers Institute (PMMI); Packaging Hall of Fame inductee "I really don't know if I can put a value on this training because this event will change my life for the next fifty to sixty years. This process could be applied to any and all aspects of work and life. Wow, what an eye-opening week!"- Brad Miller, Process Improvement Coordinator, major beverage bottler "Ron Heiskell and his ReducedEffort changeover philosophy has been so successful at our facility because it is highly relatable to the everyday worker and manager.... It is both simple and revolutionary." - Tony Coleman, Plant Manager, major beverage company "I just wanted to give you a quick update on our ReducedEffort Changeover progress. The changeover we did this afternoon was 40 minutes. Prior to the one week ReducedEffort Changeover event, the changeover time was 347 minutes."- Danielle Hess, Operations Manager, major extruder of plastics "Ron Heiskell has given the Lean world a gift: an opportunity to improve far beyond what anybody could fathom."- Paul Akers, 2 Second Lean, Lean Health, and Lean Travel "The operators in any given plant, in my opinion, know the machines better than anyone. They are, after all, the ones who have to deal with the equipment forty-plus hours a week. Ron has developed an ingenious way of bringing them together and putting their sometimes unheard ideas into action. I have seen machines go from four to five hour changeovers down to as little as twenty minutes! With his ReducedEffort changeover process I am always super confident when leading operators into a Kaizen event because there are always amazing results." - Mitch Zirkle, Improvement Methodologies leader, major bag manufacturing facility Slash changeover downtime in one week with ReducedEffort Changeover. It is the next generation of SMED and sets a new standard in rapid changeovers. ReducedEffort Changeover 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 handbook begins with a clear description of the Lean principles underlying the ReducedEffort Changeover system. Author Ron Heiskell also 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(r) method.

Download or read book Handbook of Lean Manufacturing in the Food Industry written by Michael Dudbridge and published by John Wiley & Sons. This book was released on 2011-02-02 with total page 238 pages. Available in PDF, EPUB and Kindle. Book excerpt: The principles of lean manufacturing – increasing efficiency, reducing waste, lowering costs and improving control – may be applied to any industry. However, the food industry is unique, and creates unique demands. The political, social and economic importance of food is unrivalled by any other form of produce, as is the scrutiny to which the manufacture of food is subjected. For the food industry, lean manufacturing is not simply a cost-saving strategy, but is directly linked to issues of sustainability, the environment, ethics and public accountability. Handbook of Lean Manufacturing in the Food Industry is a major new source of information and ideas for those working in food manufacturing. Offering a fresh and modern perspective on best practice, it points the way to fewer breakdowns, reduced quality faults, improved teamwork and increased profits. With a focus on operations management and new process development, the book is accessible and easy to read, and is complemented by a wealth of practical examples drawn from industry. The author’s conversational style and questioning approach will be invaluable to food manufacturers who are seeking solutions to fundamental issues. The book is directed at those who are working in food manufacturing or the wider food industry, particularly factory operations managers and training teams who are looking for resources to help with lean manufacturing implementations. Others in the supply chain, from producers to retailers, will also find it invaluable. The book is a clear and timely introduction for students and lecturers in food science and technology who want to access the reality of lean manufacturing as well as the theory.

Download or read book The Lean Healthcare Handbook written by Thomas Pyzdek and published by Springer Nature. This book was released on 2021-04-28 with total page 252 pages. Available in PDF, EPUB and Kindle. Book excerpt: The book shows readers exactly how to use Lean tools to design healthcare work that is smooth, efficient, error free and focused on patients and patient outcomes. It includes in-depth discussions of every important Lean tool, including value stream maps, takt time, spaghetti diagrams, workcell design, 5S, SMED, A3, Kanban, Kaizen and many more, all presented in the context of healthcare. For example, the book explains the importance of quick operating room or exam room changeovers and shows the reader specific methods for drastically reducing changeover time. Readers will learn to create healthcare value streams where workflows are based on the pull of customer/patient demand. The book also presents a variety of ways to continue improving after initial Lean successes. Methods for finding the root causes of problems and implementing effective solutions are described and demonstrated. The approach taught here is based on the Toyota Production System, which has been adopted worldwide by healthcare organizations for use in clinical, non-clinical and administrative areas.

Download or read book The Lean Handbook written by Anthony Manos and published by Quality Press. This book was released on 2010-11-19 with total page 357 pages. Available in PDF, EPUB and Kindle. Book excerpt: This handbook’s intention is to gather into a single reference the information related to the joint lean certification program of SME, AME, The Shingo Prize, and ASQ. This book will enhance your understanding of the certification’s Body of Knowledge (BOK) as a whole and give you a more holistic look at lean. This comprehensive handbook covers all the topics included in the BOK: cultural enablers, continuous process improvement, consistent lean enterprise culture, and business results. Written by a team of lean experts with years of experience in the field, it will be indispensible to anyone interested in implementing and sustaining a lean initiative. The book is written, by design, at the Bronze Level for certification knowledge. This means that the weightings used in the Lean BOK for the Bronze Certification were considered for the depth and breadth of material considered for each rubric. By addressing the Lean BOK at the Bronze Level, this book provides a basic understanding of the lean principles, systems, and tools at a tactical level to drive improvements with measureable results. Material from several lean practitioners with differing backgrounds and experience has been gathered to create this handbook, which serves as an ideal starting point for practitioners who want both a holistic view of lean in general and also specifically the BOK of this groundbreaking joint certification program.

Download or read book The Lean Doctors Workbook written by Aneesh Suneja and published by Quality Press. This book was released on 2010-11-19 with total page 105 pages. Available in PDF, EPUB and Kindle. Book excerpt: The content of this workbook is based on the book Lean Doctors: A Bold and Practical Guide to Transforming Healthcare Systems, One Doctor at a Time, and on the authors’ years of transforming care delivery systems with lean. The Six Success Steps discussed in the book are presented here with a focus on implementing them to achieve dramatic and sustainable change. The Success Steps are building blocks; the order in which you apply them matters. They are presented here in an order that has worked in the real world; working through them logically will help you on the path to successful implementation. Each Success Step includes a practical explanation of the theory and maps that illustrate how that particular step impacts the care process in the context of a detailed case study. The authors use several Lean mapping tools, including lean process maps, spaghetti diagrams, and swim lane diagrams. In addition to illustrating lean concepts and their application in the context of a case study discussed throughout the book, these maps provide instructive examples that can help you create similar maps for the processes you operate. With its interactive format and step-by-step design, this workbook is ideal for use in the classroom to teach Lean principles, or with a lean project team to guide a clinical implementation. Together with Lean Doctors, this workbook will help the student of lean or the lean project team learn and apply a complete lean system in a healthcare setting.

Download or read book Handbook on Continuous Improvement Transformation written by Aristide van Aartsengel and published by Springer Science & Business Media. This book was released on 2013-04-11 with total page 653 pages. Available in PDF, EPUB and Kindle. Book excerpt: This handbook provides a comprehensive and detailed framework for the implementation of "Continuous Improvement" and Lean Six Sigma in a professional project management environment. For this purpose the book brings together Lean Six Sigma and the PMBOK standard for project management. It provides an integrated approach, which can be used for both transactional and manufacturing businesses to better define ways to reduce costs, enhance processes ,and achieve faster implementation and new product or service development. The reader is guided carefully and reliably through the detailed procedures introduced in this book using a comprehensive, conceptual and practical well-balanced approach.

Download or read book Handbook of Research on Design and Management of Lean Production Systems written by Modrák, Vladimír and published by IGI Global. This book was released on 2014-01-31 with total page 487 pages. Available in PDF, EPUB and Kindle. Book excerpt: "This book explores the recent advancements in the areas of lean production, management, and the system and layout design for manufacturing environments, capturing the building blocks of lean transformation on a shop floor level"--

Download or read book Lean for the Process Industries written by Peter L. King and published by CRC Press. This book was released on 2019-06-05 with total page 373 pages. Available in PDF, EPUB and Kindle. Book excerpt: Compared to its widespread implementation across almost all areas of production, Lean improvement efforts lag within the process industries. While many innovators have successfully applied Lean principles to these industries during the past three decades, most of those pioneering efforts were never recorded to guide the improvement efforts of others. Drawing on more than 40 years of application experience at one of the world’s largest chemical and materials manufacturers, coupled with 10 years in private practice, Peter King corrects this void by providing the first comprehensive resource written explicitly for change agents within the process industries. Focusing on areas where the improvement needs of the process industry differ from parts assembly manufacturing, Lean for the Process Industries: Dealing with Complexity, Second Edition: Covers each of the eight wastes commonly described in Lean literature, looking at how they manifest themselves in process operations. Explains how to adapt value stream mapping for process operations. Shows how to identify the root causes of bottlenecks, and how to manage them to optimize flow until they can be eliminated. Provides practical techniques to overcome the barriers which have prevented the application of Cellular Manufacturing to process operations. Discusses the role of business leadership in a Lean strategy, describing both enabling and counter-productive management behaviors Since the publication of the first edition of this book, Peter King has been busy consulting with food, beverage, gasoline additive, and nutraceutical companies -- these new experiences have broadened his perspectives on certain Lean processes and have given him a richer set of examples to discuss in this new edition. While Value Stream Mapping is a very powerful tool to understand flow, bottlenecks, and waste in an operation, the traditional format as presented in many other books does not describe all of the data required to fully understand process flow and its detractors. This new edition highlights the necessary additions with examples of why they are useful. Product wheel scheduling achieves production leveling in a far more comprehensive and effective way than traditional heijunka methods. This edition has a more thorough description of the wheel concept and design steps, and more examples from actual applications.