Slide 2: SHIGEO SHINGO 1950’s in
Slide 3: Changeover or Setup ???
techniques : techniques
Slide 5: Classify setup operations into –
waste, internal setups & external setups
Eliminate the waste
Separate internal from external setup operations
Convert internal setups into external ones
Improve internal setups
Improve external setups
Document the new procedure, and actions that are yet to be completed.
Do it all again
Slide 6: STEP
Observe The Current Methodology
Slide 8: STEP
Separate Internal And External Activities
Slide 11: STEP
Convert Internal Activities Into External Activities
Slide 13: STEP
Improve The Internal And External Activities So That They Come To A Common Scale
Use checklist to avoid omission
Use locating pins and sockets
Quick release fasteners instead of bolts and nuts
Slide 15: Parallel Operations Using Multiple Operators
Effects of implementation : Effects of implementation
Slide 17: Average setup time reduced to 2.5% of the time originally required, i.e. a 97% improvement.
Elimination of setup errors reduces defect rates.
Increased safety from simpler setups.
Lower expense of setups.
Operator preferred since easier to achieve.
Lower skill requirements since changes are now designed into the process rather than a matter of skilled judgement.
Slide 18: Examples