Quick Changeover Examples (SMED) AMF Process Improvement Group 16 - - PowerPoint PPT Presentation

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Quick Changeover Examples (SMED)

AMF – Process Improvement Group

16 February 2017

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Ø OBSERVE the process

Remember the Basics

Ø IDENTIFY steps that NEED to be done whilst stopped and what CAN be done whilst it’s running Ø OPTIMISE – Shorten INT Ø MOVE INT to EXT Ø OPTIMISE – Shorten EXT

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• Early 1970’s startup called Southwest Airlines posted

loss of $1.6m.

• Forced to sell 1 of its planes within 24mths

Services – Southwest Airlines

The answer: Unload and load passengers faster than any other airline and get planes back in the air … “The 10 minute Turnaround” The following year SA posted its first profit and stayed black since

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… ruthlessly applied the principles

Southwest – How did they do it?

Park at gate Land Take-

• ff

Taxi Retrieve luggage Alight Clean Reload/ Seating Checks Push back Park at gate Land Take-

• ff

Taxi Retrieve luggage Alight Clean Reload/ Seating Checks Push back

Identified ‘External’ steps …

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• Moved INT to EXT
• Looked for parallel work opportunities

Southwest – How did they do it?

Park at gate Land Take-

• ff

Taxi Retrieve luggage Alight Clean Reload/ Seating Checks Push back

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Before and after …

Southwest – How did they do it?

Park at gate Land Take-

• ff

Taxi Retrieve luggage Alight Clean Reload/ Seating Checks Push back Park at gate Land Take-

• ff

Taxi Retrieve luggage Alight Clean Reload/ Seating Checks Push back

process time

• Reduction in turnaround (process lead time)
• Reduced costs
• Competitive edge

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• Used same aircraft (versus 10 at competitors)

Ø Interchangeability (aircraft and components) Ø Simplified mechanics training and skill set Ø Lower spares inventory Ø Same size/shape for gate access

• Point to Point Operation

Ø Less congestion than at Hubs (slot availability and volatility) Ø Less impact of weather

• Don’t charge customers for bags

Applying the Principles

• 1. Single Minute Exchange of People
• 2. Single Minute Exchange of Aircraft

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What are the obvious steps they made ‘EXTERNAL’

How Fast Can You Change a Tyre?

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Manufacturing – Quick Changeover

• Die alignment – tolerances on dowels with chamfers
• Automated coating process in cabinet whilst preparing machine
• Moved inspection to ‘External’
• Standardized ‘warm-up’ process
• Reduced the need to fetch documentation ‘Inside’ operation
• Stopped continual tampering with dies – made them compliant

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Same principles and questions need to be asked Involve process workers

Manufacturing/Assembly – Quick Changeover

Examples:

• Indexed assembly carousels
• Implement parallel activities
• Quick release clamping, or boltless clamping methods
• Snap-on hose connectors
• Positive location methods (eliminate adjustments)
• Multiple entry points to machine/assembly jigs
• Etc.

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• Less downtime
• Less inventory (smaller batches)
• Quicker turnaround (responsiveness)
• Better delivery performance
• Reduced costs
• Easier for employees

Benefits

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• SMED (Quick changeover) – improves productivity for a particular type of

problem Other lean improvement techniques improve productivity, reduce costs and improve quality Tips:

• Involve process users – (video if possible)
• Focus on the right problematic areas – not FOTM
• Standardization – codify not tacit
• Don’t take away the examples as templates – take away the principles
• Your application will be unique, but relevant

Summary and Health Warnings

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Gavin Jones gavinjones@newpotentialcbs.com www.newpotentialcbs.com 07852 595 576