Reduce Process Downtime

Step 5 - Identify the Six Losses

Course Summary

 Why Reduce Process  Downtime?
The primary focus of this training  course is on reducing process downtime. One of the largest causes of  downtime in a manufacturing facility is equipment changeovers. The time  that a piece of equipment is being changed from running one product to  run the next product it is unavailable for production. This is lost  production time which cannot be recovered. The way forward to reduce  this changeover downtime is to implement a Quick Changeover.


What is a Quick Changeover?
A Quick Changeover is a improvement  process using the SMED concept for reducing equipment downtime. The  definition of a changeover is the time between the last good part of the  current run until the first good part off the next run. The time taken  to set up a process is non-productive and therefore, non value added  from a customers perspective. It takes longer to manufacture components  because orders have to wait until the equipment can produce a good part  before an order can be started and the work completed. Lead time  increases because of long changeover times.

What are the steps in a Quick Changeover?
There are four steps to implementing SMED:
      1. Document and record a changeover to identify the activities
      2. Separate activities into internal and external elements
      3. Convert internal into external elements
      4. Streamline all aspects of the changeover process

What affect will implementing SMED have on production?
Long changeover times force a business  to manufacture large batches being product to compensate for the  downtime. Implementing quick changeovers using SMED will reduce the  amount of time to set up a machine. This will reduce lead time and  increase production hours. 


Process  Downtime?
The primary focus of this training  course is on reducing process downtime. One of the largest causes of  downtime in a manufacturing facility is machine changeovers. The time  that a piece of equipment is being changed from running one product to  run the next product it is unavailable for production. This is lost  production time which cannot be recovered. The way forward to reduce  this changeover downtime is to implement a Quick Changeover.

What is a Quick Changeover?
A Quick Changeover is a improvement  process using the SMED concept for reducing equipment downtime. The  definition of a changeover is the time between the last good part of the  current run until the first good part off the next run. The time taken  to set up a process is non-productive and therefore, non value added  from a customers perspective. It takes longer to manufacture components  because orders have to wait until the equipment can produce a good part  before an order can be started and the work completed. Lead time  increases because of long changeover times.

What are the steps in a Quick Changeover?
There are four steps to implementing SMED:
       1. Document and record a changeover to identify the activities
       2. Separate activities into internal and external elements
       3. Convert internal into external elements
       4. Streamline all aspects of the changeover process

What affect will implementing SMED have on production?
Long changeover times force a business  to manufacture large batches being product to compensate for the  downtime. Implementing quick changeovers using SMED will reduce the  amount of time to set up a machine. This will reduce lead time and  increase production hours.

Course Curriculum

Christopher Turner

After working for more than 35+ years in the continuous improvement field with clients around the world, I am personally sharing my hands-on work experience and knowledge with the world through these cost effective and self-paced online training courses.

John Gent

Manager

Highly Recommended Course. Easy to Understand, Informative, Very Well Organized. The Course is Full of Practical and Valuable for Anyone who wants to Enhance their Skills. Really Enjoyed it. Thank you!!

Course Pricing

  • Reduce Process Downtime
  • $65 USD

    Step 5 - Eliminate the six losses

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