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 written by John R. Henry and published by CRC Press. This book was released on 2017-07-27 with total page 209 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 Beyond the Lean Revolution written by Deborah J. Nightingale and published by AMACOM Div American Mgmt Assn. This book was released on 2011 with total page 289 pages. Available in PDF, EPUB and Kindle. Book excerpt: Most organizations are engaged in change efforts-often focused solely on eliminating waste in specific departments or "silos." That's the "lean paradigm," and while it's a good place to start, enterprise transformation goes much further. It begins with the big picture: What are the strategic objectives? How is the enterprise performing against those objectives? How should it be? Who are the stakeholders and what do they value? Then it moves forward toward an audacious vision of the enterprise's future. Based on years of research and implementation, Beyond the Lean Revolution provides a roadmap for achieving sustainable, bottom-line results, delivering value to stakeholders, and reaching that future vision. Filled with illuminating examples, the book moves well beyond traditional lean thinking, showing readers how to: Ensure senior leadership commitment * Assess the enterprise's current state * Analyze stakeholder values * Develop a future vision * Create a plan for transformation From inception to implementation and beyond, this book provides a holistic framework for bridging the gap from mere change ... to genuine transformation.
Download or read book Kaizen for Quick Changeover written by Keisuke Arai and published by CRC Press. This book was released on 2006-02-28 with total page 326 pages. Available in PDF, EPUB and Kindle. Book excerpt: 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.
Download or read book Improving Changeover Performance written by S. Culley and published by Elsevier. This book was released on 2001-09-26 with total page 365 pages. Available in PDF, EPUB and Kindle. Book excerpt: Improving Changeover Performance is essential reading for managers, engineers and improvement practitioners working in manufacturing industries. It will also prove invaluable to original equipment manufacturers and postgraduates and academic researchers alike. Increasing importance is being placed on responsive, flexible manufacture in multi-product industrial environments. The ability to changeover production facilities both quickly and to a high standard is a key component of just-in-time and lean manufacturing paradigms, which are increasingly being adopted as businesses strive to compete in today's volatile and congested markets. Currently industry frequently adopts the SMED (Single Minute Exchange of Die) system, a well-established shop floor method to improve changeovers. This book takes a major step beyond the SMED system, by describing in much greater detail than hitherto the potential role of engineering design, of both substantive and non-substantive nature, to enhance changeovers. It also clearly sets out what better changeover performance can contribute to business competitiveness, and describes the many pitfalls that an improvement initiative can face. - Provides overall methodology for changeover improvementIncorporates design into SMED system - Recommended by the IMechE Journal of Engineering Manufacture
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 180 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 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 707 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 Lean Expert written by Joseph Niederstadt and published by CRC Press. This book was released on 2014-12-03 with total page 176 pages. Available in PDF, EPUB and Kindle. Book excerpt: The Lean Expert: Educating and Elevating Lean Practitioners Throughout Your Organization outlines a method that can help organizations engage associates and empower them to achieve "expert status" in the nine core principles of Lean. By implementing the Lean Discipline Expert process detailed in the book, companies will demonstrate to their associates that they believe they are the organization’s greatest assets, while empowering them to make lasting improvements to the organization. The book provides a robust and proven process for creating a Lean culture. It outlines a method, with defined steps, for the development of Lean Discipline Resource People that will help associates achieve "expert status" in the core Lean principles of 5S–Visual Management, Value Stream Mapping, Standard Work, Total Productive Maintenance, Quick Changeover, Error Proofing, Process Problem Solving, Material Management, and Continuous Improvement. You will be able develop Lean strategies, create a Master Schedule, initiate activities for supporting goals and objectives, and complete a Train-the-Trainer class as well as achieve facilitation skills to teach, communicate, guide, and lead Lean overview training as well as comprehensive subject-matter training. In addition, you will understand how the Lean Discipline Expert process can help to support associate involvement at all levels and learn where and how the nine principles overlap and interact. By engaging and empowering various levels of associates throughout the organization, you will provide strength and ownership for your business and, most importantly, your associates. The book includes access to additional resources on the book’s page at www.crcpress.com. It includes a tracking mechanism for monitoring candidate progress, facilitation feedback forms, LDE checklists, and certificates of accomplishment you can use to acknowledge associates that achieve Lean Discipline Expert status.
Download or read book Lean Production for Competitive Advantage written by John Nicholas and published by CRC Press. This book was released on 2015-10-08 with total page 500 pages. Available in PDF, EPUB and Kindle. Book excerpt: The Lean concepts and principles described in this book have revolutionized manufacturing practice and business conduct in a manner similar to what Henry Ford’s system did for mass manufacturing. Lean production however, involves much more than the adoption of methods and procedures, it requires a change in management philosophy that emphasizes relationship building, trust, and responsibility being conferred to frontline workers and suppliers. Based on three decades of teaching experience, Lean Production for a Competitive Advantage: A Comprehensive Guide to Lean Methodologies and Management Practices introduces the Lean philosophy and illustrates the effective application of Lean tools with real-world case studies. From fundamental concepts to integrated planning and control in pull production and the supply chain, the text provides a complete introduction to Lean production. Coverage includes small batch production, setup reduction, pull production, preventive maintenance, standard operations, as well as synchronizing and scheduling lean operations. Detailing the key principles and practices of Lean production, the text also: Illustrates effective implementation techniques with case studies from a range of industries Includes questions and completed problems in each chapter Explains how to effectively partner with suppliers and employees to accomplish productivity goals Designed for students who have a basic foundation in production and operations management, the text provides a thorough understanding of the fundamental principles of Lean. It also offers practical know-how for implementing a culture of continuous improvement on the shop floor or in the office, creating a heightened sense of responsibility and pride in all stakeholders involved, and enhancing productivity and efficiency to improve the bottom line. Instructor’s material available – please contact: [email protected] or call 1-800-634-7064 to request these materials.
Download or read book Lean for the Process Industries written by Peter L. King and published by Productivity Press. This book was released on 2019 with total page 340 pages. Available in PDF, EPUB and Kindle. Book excerpt: Drawing on 40 years of application experience at one of the world's largest chemical and materials manufacturers, King provides the first comprehensive resource written explicitly for change agents within the process industries.
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.
