First steps
- Film one changeover.
- Mark each step internal or external.
- Move, simplify, standardise; repeat.
How to measure success
Changeover time (minutes) and batch size. Record the value before you start, so the effect of every action can be shown.
When these methods are the wrong choice
- SMED: Lines that rarely change over.
- Standard work / work instruction: Processes that are still changing every week.
- OEE analysis: Manual processes without a machine cycle.
- 5S: Process capability problems.
- SPC control charts: Characteristics without a capable gauge or with too few data.
The methods in one line
| Method | What it is |
|---|---|
| SMED | Shortens changeovers by moving work outside the machine stop and simplifying the rest. |
| Standard work / work instruction | The current best way to do a job, with key points and reasons, used for training and audits. |
| OEE analysis | Splits equipment losses into availability, performance and quality to show where time is lost. |
| 5S | Workplace organisation: sort, set in order, shine, standardise, sustain. |
| SPC control charts | Separates common-cause from special-cause variation and tells the operator when to react. |