Most managers struggle to change product changeovers or maintenance downtimes in less time.  In fact, many managers try to avoid the delays associated with changeovers and so build up unnecessary buffer inventory. Why is it important to streamline – you lose capacity every minute the process or equipment is down for the changeover. You can use the following 4 steps to make changeovers faster and less stressful.  If this applies to you, get a more complete explanation at https://www.RapidLeanCoach.com

1. Observe the process in great detail, documenting every step that takes place and how long it takes. Many teams I work with video tape the changeover and then play it back faster to analyze in detail.
2. Take the list of steps that you documented and put them in chronological order. On a spreadsheet use one column for the name of the task, one for how long it took (using a stopwatch or the video clock) and one for comments or ideas.
3. Add a fourth column to indicate each observed step that can only be performed when the process is “down.” These are your “internal changeover” steps. Every other step is something that can be done before or after the core process is changed.  These are called the “external changeover.” We must separate the “internal” steps from the “external.” We convert as many as possible internal steps into external steps.
   1. Examples of “internal” (can only be done when the process is down):
      • Detach and replace internal moving parts
      • Make adjustments to components that would be unsafe if the process was moving.
      • Sanitize an area production equipment, restaurant kitchen, operating room (without people present)
   2. Examples of “external” (could have been done before or after shutting down the process):
      • Bringing the new materials to the line or the room
      • Removing old materials from the area
      • Cleaning up the area
4. Perform these improvement steps
   1. Pre-stage all tools, materials, change parts, repair parts before you shut down the process for the changeover. Include mechanics or technicians present before shutting down. This reduces the amount of waiting time while the process is down.
   2. Wait until the process is back up before removing change parts, materials
   3. Study the remaining steps in the “internal” part of the changeover to perform them faster and right the first time. This will focus on reducing motion waste looking for tools & materials, the waste of waiting for materials or people. This directly shortens the changeover time.

Please ask one question about your changeovers in comments below so we can share improvement ideas.

For help on streamlining your changeovers contact Steve, The Rapid Lean Coach, here at https://rapidleancoach.com/contact