7 Effects of High Changeover Time
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Changeover time reduces the Availability of the machine. Higher the changeover time, the lesser the machine is available for production. And, there are many other issues that gets created due to High Changeover time.
I have listed 7 major wastes / issues created by high set up time.
Increases OverProduction - People don't do frequent changeovers (as setup time is high) and WIP builds up
High WIP results in high space requirement in the shop floor
People won’t get trained in setups as they don’t do setups frequently - resulting in high variation in setup time and poor quality setups / lot of adjustments
Increases Waiting Waste (of materials and manpower) - during setup
Continuous Flow Production would be difficult - as the setup time is high
Load Levelling (Heijunka) becomes difficult - infrequent changeovers leading to large lot size - Products which takes more setting time will be avoided by the personnel
High Risk of Product Obsolescence - Changes in specification would make the WIP obsolete
Are you facing some of these challenges in your factory?
Reduce the Changeover time using SMED techniques to see better results in the above areas. Watch this video (English / Tamil ) to learn about SMED Implementation.
2 Ideas for the Week:
He who blames others has a long way to go on his journey. He who blames himself is halfway there. He who blames no one has arrived. - Ancient Proverb
A fit body, a calm mind, a house full of love. These things cannot be bought - they must be earned. - Naval Ravikant
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