Rapid Changeover (SMED)

Traditionally, companies have maximised batch sizes in order to reduce the amount of time spent on changeovers, and minimise the number of defects associated with machine set-up. However, customers are increasingly demanding smaller and more frequent deliveries, and holding stock can be both expensive and risky.

In order to make the most effective use of equipment whilst remaining responsive to fluctuating customer demand, companies need to be able to conduct changeovers in minutes or seconds, and to be confident in the quality of products right from the first piece. This highly practical course provides delegates with a structured approach to achieving rapid changeovers, and can incorporate company-based activities if appropriate.

Course Content

Introduction to Rapid Changeovers
•Rapid Changeovers and Lean Manufacturing
•Identifying opportunities for reducing set-up & changeover times
•Rapid Changeovers & Total Productive Maintenance (TPM)
•Gaining competitive advantage from Rapid Changeovers
•Setting improvement targets: what can be achieved?

Changeover Reduction Techniques
•Measuring changeover times
•Typical changeover activities
•Classification of changeover activities
•Key improvement steps for changeover reduction
•Standardising & mistake proofing improved changeover processes
•Examples and case studies

Changeover Improvement Exercise
•Changeover observation & recording
•Identifying improvement opportunities
•Designing & implementing improvement
•The power of continuous improvement
•Additional company-based changeover exercise (where appropriate)

Implementing Rapid Changeovers
•Benefits for individuals & the company
•Overcoming barriers