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

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

Biography

Karsten Herr has studied brewing technology and mechanical engineering. He has worked for many years as an operations and production manager and as a commissioning engineer. Since 2004, he has been working as a freelance consulting engineer, training and coaching production companies. He supports production companies of all sectors, in discrete as well as in continuous industries. Projects on which he has worked range from complete production restructuring via optimizing individual value streams to one-off training courses on different topics on process and workplace organization.

He has specialized in the analysis of set-up procedures on machines and processes and the drafting of quick changeover concepts. He is regularly supporting companies with open and in-house workshops and analysis of set-ups and drafting of solutions for quick changeovers as well as running improvement projects of various scopes.

He also works as a lecturer at various universities and professional academies, where he teaches courses on organization and structuring of business processes, systems engineering and systems behavior, production organization and factory planning, and production optimization. His main focus is on Lean, TOC, TPM, QRM, and Six Sigma (Certified Black Belt).

He is has a master´s degree in management and organization from the TiasNimbas Business School, one of Europe´s top business schools.