1 Employability skills (a) Employers value people who: fit well into their team and workplace use initiative to solve routine problems work productively have good time-management skills are committed to continuous learning and improvement. Slide 1: MCMT220A Apply quick changeover procedures

2 Employability skills (b) Employability skills can: help you gain employment make you a productive and valuable worker increase your chances of promotion. Slide 2: MCMT220A Apply quick changeover procedures

3 Employability skills (c) Employability skills developed in MSACMT220A Apply quick changeover procedures: Communication Teamwork Problem-solving Self-management Planning & organising Technology Lifelong learning Initiative & enterprise Slide 3: MCMT220A Apply quick changeover procedures

4 Competitive (lean) manufacturing To be competitive companies must: keep customers satisfied increase efficiency reduce costs reduce waste respond quickly continuously improve have enthusiastic and skilled staff. Slide 4: MCMT220A Apply quick changeover procedures

5 Seven types of waste in manufacturing 1.Overproduction 2.Defects 3.Inventory 4.Motion 5.Processing 6.Transportation 7.Waiting Slide 5: MCMT220A Apply quick changeover procedures

6 Lean manufacturing tools (Kaizens) 5S Pull systems (kanban) Value stream mapping Just-in-time production Total productive maintenance Slide 6: MCMT220A Apply quick changeover procedures

7 Lean manufacturing tools (Kaizens) cont … Takt time Heijunka Jidoka Visual process control Error-proofing (poka-yoke) Waste (muda) elimination Cellular/flow production Set-up/changeover reduction Slide 7: MCMT220A Apply quick changeover procedures

8 Quick changeover The time required to change over a machine or process from one item or operation to the next item or operation. Slide 8: MCMT220A Apply quick changeover procedures

9 Understand quick changeover Understand the benefits of using quick changeover as a competitive manufacturing tool. Identify how quick changeover can reduce waste in your work area. Slide 9: MCMT220A Apply quick changeover procedures

10 Chapter 1 Understand the principles of quick changeover This chapter explains how to: 1.1 Reduce waste with quick changeover 1.2 Determine the benefits of quick changeover Slide 10: MCMT220A Apply quick changeover procedures

11 The seven wastes 1.Overproduction 2.Defects 3.Inventory 4.Motion 5.Processing 6.Transportation 7.Waiting Slide 11: MCMT220A Apply quick changeover procedures

12 Benefits of quick changeover Reduce batch sizes Increase available space Reduce inventory costs Allow product to flow from one process to the next Slide 12: MCMT220A Apply quick changeover procedures

13 Benefits of quick changeover cont … Permit uninterrupted (smoothed) production with no bottlenecks or delays Increase production flexibility Improve on-time delivery – quick changeover supports the ability to meet customer demands Increase changeover accuracy Slide 13: MCMT220A Apply quick changeover procedures

14 Benefits of quick changeover cont … Reduce defect rates Reduce start-up scrap/waste Improve equipment utilisation/yield Increase profitability without new capital equipment purchase Slide 14: MCMT220A Apply quick changeover procedures

15 Design a quick changeover You need to understand: the principles of quick changeover the design of a quick changeover procedure in order to be able to improve it. Slide 15: MCMT220A Apply quick changeover procedures

16 Chapter 2 Design a quick changeover This chapter explains how to: 2.1 Identify internal and external activities 2.2 Convert internal activities to external activities 2.3 Eliminate the need for adjustment 2.4 Remove the need to set up completely 2.5 Improve ergonomics and OHS Slide 16: MCMT220A Apply quick changeover procedures

17 Internal and external activities Internal set-up activities – can only be carried out when the machine or plant has stopped. External set-up activities – can be completed while the machine is operating. Slide 17: MCMT220A Apply quick changeover procedures

18 Design modifications Use dedicated equipment to ensure that the right equipment is always ready and waiting. Ergonomically designed mobile die carts get dies into position rapidly. Well-located and ergonomically designed tool boards improve access to necessary equipment. Press-mounted roller rails move the die into the pre-staging position. Slide 18: MCMT220A Apply quick changeover procedures

19 Design modifications cont … Quick-change die cassettes easily slide in and out of the platen. Quick-release clamps for die cassettes clamp the dies in place rapidly. Locating pins for aligning dies can remove the need to adjust the die. Standardising shut heights using a liner removes the need for press stroke adjustments. Slide 19: MCMT220A Apply quick changeover procedures

20 Ergonomics and OHS Standing is better than sitting Workstations are adjustable Work rhythm Don’t remain in one position for too long Ergonomic 5S is essential Slide 20: MCMT220A Apply quick changeover procedures

21 Implement quick changeover procedures Understand the steps involved. Understand importance of preparation, communication, teamwork. Be aware of any OHS hazards. Regularly update and improve OHS procedures. Slide 21: MCMT220A Apply quick changeover procedures

22 Chapter 3 Implement a quick changeover This chapter explains how to: 3.1 Prepare for quick changeover 3.2 Implement a quick changeover in your work area 3.3 Continuously improve procedures 3.4 Improve OHS Slide 22: MCMT220A Apply quick changeover procedures

23 Preparing for a quick changeover Know when changeover is required. Obtain all required tools, parts and materials. Communicate with everyone involved in the changeover. Slide 23: MCMT220A Apply quick changeover procedures

24 Factors for successful changeover Preparation Training Timing Teamwork communication Standardisation Right tools in the right place Slide 24: MCMT220A Apply quick changeover procedures

25 Convey information about changeovers by: production plans production kanbans (pull systems) noticeboards toolbox talks work authority. Slide 25: MCMT220A Apply quick changeover procedures

26 Materials required Standard operating procedures (SOP) Job safety analyses Work permits Pre-start checklist Authority to change Quality criteria Control charts Data collection tools Slide 26: MCMT220A Apply quick changeover procedures

27 Pre-start checklist for die changeover Before you begin the die changeover, check that you have:  informed all relevant persons  positioned the tool board  positioned the new die in the pre-staging area  prepared die and accessories by performing external set-ups  electrically and mechanically isolated the equipment  removed all hazards in the work area. Slide 27: MCMT220A Apply quick changeover procedures

28 Review changeover How did we perform? Where there any problems? Are we improving? What recommendations can we make? Identify, discuss and document improvements. Slide 28: MCMT220A Apply quick changeover procedures

29 PDCA cycle Plan ahead for changeTake action to improve the process Execute the plan, taking small steps in controlled circumstances Study the results Slide 29: MCMT220A Apply quick changeover procedures

30 Improve OHS in quick changeovers Undertake regular job safety analyses Update procedures Retrain Slide 30: MCMT220A Apply quick changeover procedures

31 Job safety analysis 1.Document the activity 2.Identify the hazards 3.Document the control measures 4.Identify who is responsible 5.Monitor and review Slide 31: MCMT220A Apply quick changeover procedures