7 Side Effects of High Changeover Time
and how to reduce it? + 2 Quotes and 1 Activity to kindle your thoughts.
1 Article for the Week:
High Changeover time is one of the major challenges people face in a manufacturing shopfloor.
It not only affects the productivity, but also has 7 major side-effects
Side Effects of High Changeover Time:
Increases OverProduction - People don't do frequent changeovers (as setup time is high) and WIP builds up - require more bins and material handling equipments
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. So Batch Production would be followed
Load Levelling (Heijunka) becomes difficult - infrequent changeovers leading to large lot size - some products will not be produced that often to meet the demand
High Risk of Product Obsolescence - Changes in specification would make the WIP obsolete
It is very important to reduce the change-over time of the machines. Single Minute Exchange of Dies (SMED) is a Lean Manufacturing tool that is used to reduce the change-over time. You can watch this video in Youtube to learn about SMED and start implement in your company
2 Quotes for the Week:
“If you want something new, you have to stop doing something old” - Peter F. Drucker
“Efficiency is doing the thing right. Effectiveness is doing the right thing.” - Peter F. Drucker
1 Activity for the Week:
“Something is wrong if workers do not look around each day, find things that are tedious or boring, and then rewrite the procedures. Even last month's manual should be out of date” - Taiichi Ohno
Can you go around your shopfloor and see how many old / obsolete documents are displayed in the work place? What can you do about them? Please share it in the comments section.
Great share and the quotes are so perfectly apt. Thanks for sharing.