Why Reducing Changeover Time is Important?
7 Reasons to reduce changeover time + 2 Quotes from me and 1 Video
Most professionals think that Changeover time cannot be reduced beyond a particular time. If they think it will take 2 hours for a setup change, they hardly make a plan to reduce the same. Even after a lot of training, people are skeptical on this.
However, Changeover times can be reduced by more than 50% with ZERO additional cost.
Why is reducing Changeover Time important?
Here are 7 reasons:
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 - 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
If the Changeover time is high in your company, check out the video below that helps in reducing the setup time.
Share this with your friends and colleagues.
Video: How to reduce Changeover time in your operations?
2 Quotes from me:
Standard work frees the mind to improve.
Stability is the doorway to improvement.
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