Carlo Scodanibbio - Industrial Consultant

Training Course Program
Achieving Quick Change-Over - 1-day workshop

...a critical "stepping-stone" towards Lean Manufacturing...

workshop contents and main topics

World Class Manufacturing: the scenario. (--> read more about) - Value Adding Management in the manufacturing industry: the pilot light and driving philosophy for the new millennium. Focusing on processes to maximise value and eliminate waste. (--> read more about)
Productive process time and cost analysis: identifying value-adding and non-value-adding operations. "Push" and "Pull" productive methods. Why and when the traditional "push" approach should be abandoned. (--> read more about)
Batch and Line Operations - the large-variety/small-lot situation. Why the traditional "Economic Order Lot" principle is today obsolete.
Movie-time: the negative effects of long change-over operations. The "stock" issue. Detrimental effects on people morale. The final result: brain laziness.
Simulation: why traditional change-over time is too long.
Foundations of Achieving Quick Change-Over (AQCO): Team improvement to set-up activities. (--> read more about). Distinguishing between Internal and External set-up. The correct approach to Workplace Management. Converting internal to external set-up. Improvements in external set-up activities. Improvements in internal set-up activities.
Techniques, hints and tips for Quick Change-Over: Parallel operations - "Bolts and nuts are our enemies" - Functional clamping - Elimination of adjustments - Eliminating all residual waste - Benefits of video recording.
"Single-minute" and "one-touch" Change-Over. Case study: how to reduce a set-up time from 1 hr to 2 minutes.
People and Quick Change-Over: TEI-Total Employee Involvement is the ideal discipline to approach an AQCO project. (--> read more about)
Achieving Quick Change-Over: a cultural revolution.

workshop duration

Duration: 8 hours

workshop objectives

This workshop is designed to give participants a practical, "hands-on" overview of the Achieving Quick Change-Over discipline, aimed at reducing drastically all set-up times (die-changing, mould-changing, re-tooling, line setting, etc.).
Through Quick Change-Over, manufacturers may finally open the door to Lean Manufacturing and Flow Production practices, and target at large-scale improvements in productivity, quality and reactivity to clients' needs and expectations (World Class Manufacturing status).

The workshop is very interactive, complemented by practical exercising and supported by appropriate case studies.
Participants will be guided through a step-by-step process that will lead to set-up time reductions of up to 80%, and, in many instances, to "one-touch change-over".
Besides, participants will understand the strategic importance of fast change-overs for modelling a "flow" style of production, the heart of World Class Manufacturing. Basic concepts of Flow Production/Lean Manufacturing, Cell Production, Multi-Process Operations, "in-process Quality Control", Total Productive Maintenance and Total Employee Involvement will be illustrated, as well as their relations to the AQCO discipline.
Participants will be given operational guidelines and criteria for the introduction and development of valid AQCO programs within their own organisations, and furnished with practical hints to identify those opportunity areas in which pilot AQCO projects should be implemented.

This course is very interactive and supplemented with abundant practical exercises and case studies

target audience

General Managers, Operations and Production Managers and Supervisors, Plant Managers and Engineers, Maintenance and Tool-Shop Managers, from manufacturing enterprises.

enquiries

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