✔ Minimizes changeover loss by optimizing production order sequence planning
✔ Supports SMED method by optimizing internal operations
✔Strengthens the OEE improvement culture
✔Prevents loss of quality due to changeover errors
Switching a production line from one product to another is often a relatively time-consuming process. Ever smaller production runs and thus a growing number of product changes make changeover time loss one of the largest and fastest growing OEE losses. The changeover time reduction module gives you more insight and supports you in reducing this loss.
First, the module calculates a planned or achievable changeover time for each transition. With this information, planning can easily determine an optimal production order sequence for each line so that ultimately the least amount of time is lost.
The most commonly used technique for reducing changeover time is the SMED-method (Single Minute Exchange of Die). SMED divides the changeover process into internal operations (executable only when the machine is not producing) and external operations (executable with the machine still running). Improvement occurs by:
Changing internal operations to external operations as much as possible
Optimizing remaining internal operations
A clear step-by-step changeover instruction provided with pictures and/or videos helps the operator to correctly perform the requested tasks. The instruction is available prior to the scheduled changeover.
Operator avoids unnecessary loss of time as he/she can request missing materials, special tools and/or assistance ahead of time via the user interface.
Presentation of remaining scheduled changeover time raises awareness among participants.
Seen purely from the machine's perspective, every changeover is an availability and therefore an OEE loss. In other words, food for thought for the improvement teams who will optimize the changeover operations using the SMED method. This is only part of the improvement success because with MyPlantFloor we also keep users informed in real time of the OEE performance per order and per service. So as not to lose them in the OEE improvement culture, in the real-time feedback we calculate the calculated changeover time as a planned loss that does not affect the OEE number. Any exceeding of the calculated changeover time does represent a loss.
Changeover errors often lead to extra work, rejects or, in the worst case, a recall with all the financial consequences. The changeover reduction module also offers the ability to work with a machine release list. The release list is a checklist that serves as a reminder for the rebuilders. Any mandatory approval by a quality officer is a prerequisite for releasing a production line for production. This way of working reduces the risk of errors.
Thanks to awareness, adjustment of production line components, better and available tools, training and/or better coordination, the loss due to changeovers, will be drastically reduced. Something that is clearly reflected in the changeover time summary report. The improvement team can easily adjust each time gain per changeover operation, with the result that the proposed changeover time remains correct.
Do you want to implement changeover time reduction steps? Feel free to ask our experts for more information or request a demo right away and experience it for yourself! Contact us, call +31 76 5156572 or email info@agilitec.nl.
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