Ortiz - The Quick Changeover Playbook: A Step-by-Step Guideline for the Lean Practitioner

This Quick Changeover Playbook is your guideline for implementation and is written for the pure Lean practitioner looking for a training tool and a guideline that can be used in the work area while improvements are being conducted. There is no other book, manual, or reference guide that provides color images and detailed step-by-step guidelines on how to develop and implement quick changeover concepts. The Quick Changeover Playbook is not a traditional book, as you can probably see. It is not intended to be read like another Lean business book. The images in this playbook are from real quick changeover implementations, and I use a combination of short paragraphs and bulleted descriptions to walk you through how to effectively reduce setup times on equipment.

Little or no time is wasted on high-level theory, although an introductory portion is dedicated to the 8 Wastes and Lean metrics. An understanding of wastes and metrics is needed to fully benefit from this playbook. This is not to imply that high-level theory or business strategies are not valuable; they are highly valuable. This playbook is for implementation, so it will not contain filler information.

Chapter 1 is a preliminary chapter and covers the basics of setup reduction and quick changeover and provides a foundation for a better understanding of the concepts in the remaining chapters. It goes over the four basic steps in a setup and explains the difference between a setup and a changeover. Often, these concepts are intermixed as having the same definition, but they are two very different steps in the whole process.

Data collection is covered in Chapter 2. Data collection is a critical piece in reducing setup times; this chapter goes into depth on how to properly collect time and motion studies specific to machines. Spaghetti diagram exercises also are discussed. Reviewing the data collected sets the tone for where improvements to overall setup and changeover can be seen. Sample forms, examples, and step-by-step pictures are included.

Using information collected from the spaghetti diagram and general waste analysis, Chapter 3 outlines the first pass of waste reduction through the implementation of the visual workplace and layout improvements. We revisit the concept of 5S (Sort, Set in Order, Scrub, Standardize, and Sustain) and visual organization because, in many cases, the one contributing factor to long setups is that the work environment provided for the operator is unorganized and cluttered. Images and illustrations from the 5S Playbook are used as well, but I include new pictures specifically in relation to setup reduction.

Chapter 4 is dedicated to two quick changeover concepts: intermediate tooling and one-turn methods. This chapter is unique and is one of the few, if not the only, reference books on the market to show examples of these concepts in real life. Intermediate tooling is a concept of converting internal work (machine off) into external work (machine on). It greatly reduces changeover times and allows for more output. The one-turn method is a concept of reducing or eliminating turning operations when removing paneling or tooling that has threaded fasteners. A sample one-turn method assessment form is provided as well. Once you have implemented the visual workplace, most of the improvements come in the form of machine modifications, engineering ideas, and maintenance changes. Physical changes and upgrades to equipment can have a profound impact on changeover; this chapter provides examples of these two concepts. However, working knowledge and technical expertise of the machines at your facility are needed to make customized improvements.