Internal Setup

Internal Setup, also known as Machine Changeover or Equipment Changeover, is a critical aspect of Lean Manufacturing. It refers to the process of switching a production machine from one product or production run to another. This process can be time-consuming and impact the overall efficiency of a manufacturing plant. For this reason, Lean experts have developed techniques to optimize the Internal Setup process and minimize downtime.

The Internal Setup process can be seen as a non-value-adding (NVA) activity. NVA activities are those that do not directly contribute to the production of a good or service. In the case of Internal Setup, it is necessary but does not add any value to the final product. The goal of Lean is to minimize NVA activities, and the Internal Setup process is no exception.

One of the key strategies for optimizing Internal Setup is to standardize the process. This can be achieved by creating detailed Standard Operating Procedures (SOPs) that outline each step of the setup process. SOPs should include clear instructions, diagrams, and photos to help guide employees through the process. The SOPs should also be reviewed and updated regularly to ensure they are up-to-date and accurate.

In addition to standardizing the process, Lean experts also focus on reducing the time required for Internal Setup. This can be achieved through a combination of reducing the number of steps required and streamlining the process. For example, the use of Quick Changeover fixtures or tools can reduce the time required to changeover a machine. Other strategies include minimizing the number of tools required, using visual aids to guide employees through the process, and using checklists to ensure all steps are completed.

Another important aspect of optimizing Internal Setup is employee engagement and involvement. Lean experts believe that employees who are involved in the process are more likely to take ownership of the process and be more committed to making it as efficient as possible. Encouraging employees to identify areas for improvement and participate in Kaizen events can also help drive continuous improvement.

Finally, it is important to monitor and evaluate the Internal Setup process on a regular basis. This can be done by tracking key performance indicators (KPIs) such as changeover time, number of changeovers, and machine downtime. The KPIs can be used to identify areas for improvement and measure the success of continuous improvement initiatives.

In a nutshell, Internal Setup is a critical aspect of Lean Manufacturing and Operational Excellence. To optimize the process and minimize downtime, Lean experts focus on standardizing the process, reducing the time required, involving employees, and monitoring and evaluating the process. By following these principles, manufacturers can achieve a more efficient and streamlined Internal Setup process, resulting in increased productivity, reduced waste, and improved bottom-line results.

Change Over

Change overs refer to the process of switching a production line from producing one product to producing another. This process can have a significant impact on the efficiency and profitability of a manufacturing operation, and as a Lean Management Expert, I would like to provide an overview of change overs and how they can be improved with SMED (Single Minute Exchange of Dies) Workshops.

One of the main challenges with change overs is the time it takes to complete the process. In many cases, change overs can take several hours or even days, which can result in decreased production and increased costs. This can be a significant issue for manufacturers who need to be able to switch between products quickly and efficiently to meet customer demand.

Another challenge with change overs is the potential for mistakes and errors during the process. When a production line is being changed over, there is an increased risk of mistakes being made, such as incorrect parts being installed or procedures being skipped. This can result in decreased production quality, increased defects, and increased lead time.

In order to improve change overs, manufacturers can implement SMED Workshops. SMED Workshops are designed to streamline the change over process and reduce the time it takes to switch between products. This is achieved by identifying and eliminating non-value-added activities, such as time spent waiting for equipment to cool down or procedures that can be done in parallel. By eliminating these activities, SMED Workshops can significantly reduce the time it takes to complete change overs, allowing manufacturers to increase production efficiency and responsiveness.

SMED Workshops also help to reduce the potential for mistakes and errors during change overs by standardizing the process and reducing the number of activities that need to be performed. This can improve overall production quality, reduce defects, and increase customer satisfaction.

In nutshell, change overs can have a significant impact on the efficiency and profitability of a manufacturing operation. By implementing SMED Workshops, manufacturers can streamline the change over process, reduce the time it takes to switch between products, and improve production quality and customer satisfaction. As a Lean Management Expert, I recommend that manufacturers consider implementing SMED Workshops as a means of improving their overall production efficiency and competitiveness.