1st Edition

The Quick Changeover Playbook A Step-by-Step Guideline for the Lean Practitioner

By Chris A. Ortiz Copyright 2016
    73 Pages 62 Color Illustrations
    by Productivity Press

    74 Pages
    by Productivity Press

    This book covers the basics of setup reduction and quick changeover and data collection. It outlines the first pass of waste reduction through the implementation of the visual workplace and layout improvements. The book covers two quick changeover concepts: intermediate tooling and one-turn methods.

    Setup and Quick Changeover
    Removing and Mounting Components in Machine (Changeover)
    Trial Runs and Final Adjustments
    Four Setup Steps
    External and Internal Setup Steps

    Data Collection
    Time Studies
    Spaghetti Diagrams

    5S and Layout Improvements
    End-of-Day Cleanup Procedure
    Daily Walkthrough
    5S Audit Form/Criteria
    5S Tracking Sheet

    Intermediate Tooling and One-Turn Methods
    Intermediate Tooling

    Visual Management
    Startup Boards
    Work Instructions
    Production Control Boards

    After Improvements
    Impact on Cycle Time
    Low and Infrequent Use


    Definition of Terms



    Chris Ortiz is the founder of Kaizen Assembly, a Lean manufacturing training and implementation firm in Bellingham, Washington. Chris has been featured on CNN Headline News on Inside Business with Fred Thompson. He is the author of multiple books on Lean manufacturing.

    Chris Ortiz is a frequent presenter and keynote speaker at conferences around North America. He has also been interviewed on KGMI radio and the American Innovator and has written numerous articles on Lean manufacturing and business improvement for various regional and national publications.

    Kaizen Assembly’s clients include industry leaders in aerospace, composites, processing, automotive, rope-manufacturing, restoration equipment, food-processing, and fish-processing industries.

    Chris Ortiz is considered an expert in the field in Lean manufacturing implementation and has over 15 years of experience in his field of expertise.