How to Get Started: Part Six - Implementation III: Quick Change Workshop How To: Part 3
I've been hammering away at Quick Change for several posts, so this will be my last. Remember, I presented this as the basic agenda for the Quick Change Workshop:
Hour in the Classroom
I reviewed the quick change basics in an earlier post. I've also posted the Powerpoint slides I use but here they are again.
Observation
Don't make the observation any more complicated than it needs to be. In other words, you don't need to track every motion or record every second of activity. I usually track major activities and put a time for each. Take notes about what goes on, what goes wrong, that sort of thing. Remember, that you're not doing a time and motion study, you're just getting a sense of the overall approach to the changeover. Again, you are especially looking for steps that can be moved to external.
You may need several folks taking notes if there are several operators acting in parallel.
Review and Analysis
Some of this will take place during the observation itself and the team identifies and discusses improvement opportunities as they see them. The rest of it will take place back in the classroom. Get the team to brainstorm ideas for improvement. Don't be shy about suggesting your own ideas.
Developing a Followup List
This is simply a matter of taking the best brainstormed ideas and turning them into action items with assigned responsibilities and deadlines.
Scheduling Team Meetings
In my experience, it's essential for the team to meet at least a few times to review the Followup List and review progress on actual changeover time reduction.
- Spend about an hour in the classroom, covering quick change basics, especially the differencebetween internal and external changeover steps.
- Go out toeither observe (that's the ideal, IMHO) or videotape a changeover. (Ofcourse, perhaps you can observe AND videotape a changeover.)
- Review the videotape or observation notes and develop ideas for:
- Moving "internal" steps to external, and
- Streamlining remaining internal steps.
- Developing a followup list.
- Scheduling changeover team meeting.
Hour in the Classroom
I reviewed the quick change basics in an earlier post. I've also posted the Powerpoint slides I use but here they are again.
Observation
Don't make the observation any more complicated than it needs to be. In other words, you don't need to track every motion or record every second of activity. I usually track major activities and put a time for each. Take notes about what goes on, what goes wrong, that sort of thing. Remember, that you're not doing a time and motion study, you're just getting a sense of the overall approach to the changeover. Again, you are especially looking for steps that can be moved to external.
You may need several folks taking notes if there are several operators acting in parallel.
Review and Analysis
Some of this will take place during the observation itself and the team identifies and discusses improvement opportunities as they see them. The rest of it will take place back in the classroom. Get the team to brainstorm ideas for improvement. Don't be shy about suggesting your own ideas.
Developing a Followup List
This is simply a matter of taking the best brainstormed ideas and turning them into action items with assigned responsibilities and deadlines.
Scheduling Team Meetings
In my experience, it's essential for the team to meet at least a few times to review the Followup List and review progress on actual changeover time reduction.
Posted by George Bohan at Thursday, September 10. 2009 
Categories: How to Implement Lean Manufacturing, Quick Changeover
Categories: How to Implement Lean Manufacturing, Quick Changeover
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