Quick Changeover Concepts Applied: Dramatically Reduce Set-Up Time and Increase Production Flexibility with SMED

Shifting from external to internal set-up steps and optimizing your set-up procedure is only the first step in achieving world-class performance. What’s most important is what comes next, cutting down internal set-up times and achieving changeovers that last only a few minutes.
Quick Changeover Concepts Applied: Dramatically Reduce Set-Up Time and Increase Production Flexibility with SMEDprovides a comprehensive overview of changeovers from a strategic, tactical, and operational perspective. It outlines specific strategies that can help readers shorten internal set-up steps through the physical analysis of machine elements. The method presented is the result of a synthesis of Shigeo Shingo’s classic single-minute exchange of die (SMED) methodology with modern engineering techniques. 
Providing readers with the understanding required to significantly reduce internal set-up times, the book explains why efficient changeovers are critical to production scheduling. It redefines set-up and set-up time and details a step-by-step method for developing quick changeover methods in a manner where changes can be realized with minimal spending. Properly implemented, the quick changeover concepts presented, can help you reduce set-up times by up to 95 percent.
The book uses language that is easy to understand to make it accessible to all functions along the value stream—from shop floor operators and industrial engineers to machine designers. It introduces the concept of systems engineering, explains the set-up process and its various elements, and addresses the financial aspects of set-up.
Maintaining an analytical focus, the text describes the theoretical details and includes numerous application examples for every step. It also includes an extensive chapter on fasteners and connection material that presents alternative methods to connect elements that can save you valuable time.

Table of Contents

Production Systems in Dynamic Markets 

Set-Up in Production 
Changeover in Production Scheduling
Faulty Assumptions 
Objective
Exception 
Definitions 

Systems Thinking 
The System 
Analysis vs. Synthesis
Top-down – Outside-In 

Product Portfolio and Process 
Strategy 
ABC Analysis Product Portfolio Analysis
Process Objective
Standardization
Appropriate Process 

Elements of the Set-Up 
General Structure of the Set-Up 
Areas of the Set-Up 
Categories
Internal and External Execution of Tasks 
Avoiding Waste 

Analysis of a Set-Up 
Taking the Video
Video Analysis 
Data Analysis
Consequences 

Function, Process Force, and Interface Analysis 
Design of Machine Elements 
Function and Process Force Analysis 
Material Choice 
Degree of Freedom 
Process Forces and Counterforces 
Form-Fit before Force-Fit 
Divertion of Process Forces 
Interface Analysis 
Function Integration 
Designing Machine Elements and their Interfaces 

Mechanical Fastening
Mechanical Fastening Theory 
Connections and Fastenings 
Alternative Connections and Fastenings 
Hose and Cable Connections 

Positioning, Setting, and Adjustment 
Positioning vs. Adjusting
Adjusting – the Right Way 
Control 

Organization 
Organization of Work Steps 
Environmental Organization

Communication
Documentation 
Before and After 

Financial Aspects
Internal
External 

Implementation Examples
Press 
Sheet Bending Line 
Rollforming Machine 

Bibliography 
Index

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