Quick Changeover Concepts Applied : Dramatically Reduce Set-Up Time and Increase Production Flexibility with SMED book cover
1st Edition

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

ISBN 9781466596313
Published December 10, 2013 by Productivity Press
168 Pages 62 B/W Illustrations

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Book Description

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.

Table of Contents

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


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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.