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Quick Changeover Examples (SMED)

AMF – Process Improvement Group 16 February 2017

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Ø  OBSERVE the process

Remember the Basics

Ø  IDENTIFY steps that NEED to be done whilst stopped and what CAN be done whilst it’s running

Ø  OPTIMISE – Shorten INT

Ø  MOVE INT to EXT

Ø  OPTIMISE – Shorten EXT

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•  Early 1970’s startup called Southwest Airlines posted loss of $1.6m.

•  Forced to sell 1 of its planes within 24mths

Services – Southwest Airlines

The answer: Unload and load passengers faster than any other airline and get planes back in the air … “The 10 minute Turnaround” The following year SA posted its first profit and stayed black since

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… ruthlessly applied the principles

Southwest – How did they do it?

Park at gate Land Take-

off Taxi Re

trieve

lug

gage

Alight Clean Reload/

Seating Checks

Push

back

Park at gate Land Take-

off Taxi

Retrie

ve

lugga

ge

Alight Clean Reload/ Seating Checks

Push

back

Identified ‘External’ steps …

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•  Moved INT to EXT •  Looked for parallel work opportunities

Southwest – How did they do it?

Park at gate Land

Take-off

Taxi

Retrie

ve

lugga

ge

Alight

Clea

n Reload/ Seating

Chec

ks

Push

back

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Before and after …

Southwest – How did they do it?

Park at gate Land

Take-off

Taxi

Retrie

ve

lugga

ge

Alight

Clea

n Reload/ Seating

Chec

ks

Push

back

Park at gate Land Take-

off Taxi

Retrie

ve

lugga

ge

Alight Clean Reload/ Seating Checks

Push

back

process time

•  Reduction in turnaround (process lead time) •  Reduced costs •  Competitive edge

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•  Used same aircraft (versus 10 at competitors) Ø  Interchangeability (aircraft and components) Ø  Simplified mechanics training and skill set Ø  Lower spares inventory Ø  Same size/shape for gate access

•  Point to Point Operation Ø  Less congestion than at Hubs (slot availability and volatility) Ø  Less impact of weather

•  Don’t charge customers for bags

Applying the Principles

1. Single Minute Exchange of People

2. Single Minute Exchange of Aircraft

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What are the obvious steps they made ‘EXTERNAL’

How Fast Can You Change a Tyre?

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Manufacturing – Quick Changeover

•  Die alignment – tolerances on dowels with chamfers •  Automated coating process in cabinet whilst preparing machine •  Moved inspection to ‘External’ •  Standardized ‘warm-up’ process •  Reduced the need to fetch documentation ‘Inside’ operation •  Stopped continual tampering with dies – made them compliant

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Same principles and questions need to be asked Involve process workers

Manufacturing/Assembly – Quick Changeover

Examples: •  Indexed assembly carousels •  Implement parallel activities •  Quick release clamping, or boltless clamping methods •  Snap-on hose connectors •  Positive location methods (eliminate adjustments) •  Multiple entry points to machine/assembly jigs •  Etc.

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•  Less downtime •  Less inventory (smaller batches) •  Quicker turnaround (responsiveness) •  Better delivery performance •  Reduced costs •  Easier for employees

Benefits

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•  SMED (Quick changeover) – improves productivity for a particular type of problem Other lean improvement techniques improve productivity, reduce costs and improve quality

Tips: •  Involve process users – (video if possible) •  Focus on the right problematic areas – not FOTM •  Standardization – codify not tacit

•  Don’t take away the examples as templates – take away the principles •  Your application will be unique, but relevant

Summary and Health Warnings

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Gavin Jones gavinjones@newpotentialcbs.com www.newpotentialcbs.com 07852 595 576