1st Edition

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

By Karsten Herr Copyright 2014
    168 Pages 62 B/W Illustrations
    by Productivity Press

    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 SMED provides 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.

    Production Systems in Dynamic Markets

    Set-Up in Production
    Changeover in Production Scheduling
    Faulty Assumptions

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

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

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

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

    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

    Organization of Work Steps
    Environmental Organization

    Before and After

    Financial Aspects

    Implementation Examples
    Sheet Bending Line
    Rollforming Machine



    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.