Introduction
Definitions
Changeover
The 3 Ups
Changeover Time
Downtime
Quality
Importance of Changeover
Pit Stops
History of Changeover
Tactic or Strategy?
The ESEE Concept
Changeover Costs
Knowing Your Costs Is Critical
WIIFM
Tangible Costs of Changeover
Lost Production
Lost Capacity
Reducing Changeover Times Creates Additional Capacity
Impact on Inventory
Labor Costs
Product and Material Losses
Intangible Costs
Response to the Customer
Capacity Utilization
Quality
Stress on People, Machines, and Systems
Reduced Innovation
Conclusion
Standard Operating Procedures
Cleaning Is Inspecting
Graphical SOPs
Writing the SOP
Electronic SOPs
Conclusion
Eliminate
Product Design
Documentation
Quality Clearance
Schedule Production Weak to Strong
Building Design
Separate Clean and Dirty
Don’t Clean Unused Equipment
Batch Versus Continuous Processing
Label Position
Cam
Ladders
Quick Connectors
Pucks
Servo Motors
Machine Covers
Eliminate Conveyor Rail Adjustment
Multiple Photoeyes
Kit Manufacturing
Preset Timing Adjustments
Movable Motor Mounts
Sprockets and Gears
Conclusion
Simplify
Smooth Surfaces for Cleaning
Washroom
Drying
Conveyors
Machine Cabinets
Clean-in-Place
Pigs
Tools
No Tools
Hand Knobs and Levers
Quick-Acting Knobs and Levers
Spring-Lock Collar
Pins
Snaps
Magnetic Locking
Vacuum Mounting
Tool-less Plunger Mount
Quarter-Turn Fasteners
Tool Changers
Toggle Clamps
Conical Cylinder Locks
Interrupted Threads
Slots and Keyholes
C Washers
One-Touch Guide Rail Adjustment
Single-Point Adjustment (Double Lead Screw)
Captive Washers
Unitary Lane Spacers
Asymmetric Parts
Scissor Jacks
Changepart Identification
Conclusion
Externalize
Material Handling
Changepart and Tool Handling
Standardized Components
Pre-heating
Duplicate Components
Clean-in-Place
Dual Rollstands
Testing
Conclusion
Execute
Speed
Positioning
Scribe Marks
Scales
Gauges
Thickness Gauge
Leaf Gauge
Digital Indicators
Micrometer Adjusters
Adjusting Stops and Jacking Screws
Use the Force
Conclusion
Develop and Implement a Program
Process or Project?
Forming the Team
Starting the Team
Who Performs Changeovers
Getting to Work
Conclusion
Appendix
Biography
John R. Henry
