Quick Changeover with REDUCE

This module will look to answer two main questions:

1. What is SMED?

2. What is the REDUCE Methodology?

In this lecture you will learn about some of the Benefits associated with implementation of the REDUCE Methodology.

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Before we start discussing the details of the REDUCE Methodology we first need to dig in and understand a few terms that you have been exposed to already.  These terms will help you understand the different aspects of your Quick Changeover and hone in on opportunities much quicker.

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Before improving anything we must first consider the current state or common problem areas of what we are improving. In the case of setups, changeovers or turnarounds there are traditionally 4 basic steps where problems and opportunities fall. Those steps are:

1. Preparation.

2. Removing and Mounting Tools and Parts

3. Calibration.

4. First Articles, Trial Runs and Adjustments.

You will learn about these 4 phases in this lecture.

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In this module, participants will be introduced to the REDUCE methodology.  You will learn:

• What the REDUCE Methodology is.

• What the REDUCE Methodology is Based on.

• The Six Steps in the REDUCE Methodology.

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In the first phase of the REDUCE methodology your focus is on deciding what data to collect.  In this first lecture Lean Strategies International LLC will suggest:

• What data to look for.

• Characteristics of a setup or changeover that you may want to REDUCE.

In this lecture students will learn about three different methods they can use to make their setup visual.

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Of all the steps in a setup or changeover reduction, separating internal and external activities may in fact be the most important as well as the simplest steps you can take.  In this lecture participants will be introduced to three tools borrowed from the SMED System to help separate external and internal operations.

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In this lecture we will look at one tool that you can use to ensure you have everything you need to REDUCE your Setup or Changeover Time.

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  In this lecture students will learn about using Function Checks to ensure that tooling, materials and machines are working correctly.  This can help REDUCE your setup times.

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In this lecture Lean Strategies International LLC will introduce one technique that you can use to reduce your downtime by separating Internal and external tasks or differentiating internal and external tasks.  External tasks have ample opportunity to reduce forms of waste.

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In this lecture we will learn about some of the methods you can use to convert internal activities to external activities.  You will learn techniques that can be used to help you REDUCE internal setup times and undergo further conversion.

Since much of the focus of the REDUCE methodology and SMED is focused on internal and external activities, cleaning up the process you will learn about two main areas that you can further Clean up or Streamline your process.

1. Improve/Eliminate the remaining external activities.

2. Improve internal activities.

One of the first things we can do to further clean up our internal setup activities is to analyze and implement parallel operations.  In this lecture Lean Strategies International LLC will explain:

• What Sequential operations are.

• What parallel operations are.

• Show examples of each.

• Learn what a procedural chart is and see an example of one.

It may seem like nuts and bolts are needed to complete your internal setup activities.  In this lecture we will dig into a few of Shigeo Shingo’s legendary tips from the book A revolution in manufacturing, the SMED system and learn about some functional clamping methods.

As was already mentioned, trial runs and adjustments can account for about 50% of your traditional setup time.  In this lecture you will be introduced to three principles that can help you eliminate adjustments in your internal setup:

• Use of numerical scales and standardization of settings.

• Make visual center lines and reference planes or points.

• Use of the least common multiplier system.

In this lecture Lean Strategies International LLC will briefly discuss one final method that can be used to reduce Internal Setup Time.  Mechanization should only be implemented with a positive cost to benefit analysis and after every effort has been made to improve already.

While much of the REDUCE Methodology is focused on identifying, converting and innovating internal and external tasks, eliminating waste is also a big part of REDUCING changeover times.  Despite this fact, you still need to ensure that your new setup process works.  In this lecture Lean Strategies International LLC will give you some valuable tips that will help you ensure the process is repeatable.

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This module will share with students how they can obtain certification from Lean Strategies International.

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