Table Of ContentQuick Changeover
Concepts Applied
Dramatically Reduce Set-Up
Time and Increase Production
Flexibility with SMED
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K a r s t e n H e r r
Quick Changeover
Concepts Applied
Dramatically Reduce Set-Up
Time and Increase Production
Flexibility with SMED
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Quick changeover: Applying set-up reduction v
About the author ix
Preface xi
Introduction xiii
1. Production systems in dynamic markets 1
2. Set-up in production 7
2.1 Changeover in production scheduling 7
2.2 Faulty assumptions 10
2.3 Objective 11
2.4 Exception 14
2.5 Definitions 16
3. Systems thinking 19
3.1 The system 19
3.2 Analysis vs. synthesis 20
3.3 Top-down – Outside-in 21
4. Product portfolio and process 23
4.1 Strategy 24
4.2 ABC analysis product portfolio analysis 26
4.3 Process objective 28
4.4 Standardization 31
4.5 Appropriate process 33
5. Elements of the set-up 35
5.1 General structure of the set-up 35
5.2 Areas of the set-up 37
5.3 Categories 39
5.4 Internal and external execution of tasks 40
5.5 Avoiding waste 41
6. Analysis of a set-up 45
vi Quick changeover: Applying set-up reduction
6.1 Taking the video 46
6.2 Video analysis 48
6.3 Data analysis 53
6.4 Consequences 54
7. Function, process force, and interface analysis 55
7.1 Design of machine elements 56
7.2 Function and process force analysis 57
7.3 Material choice 58
7.4 Degree of freedom 59
7.5 Process forces and counterforces 60
7.6 Form-fit before force-fit 61
7.7 Diversion of process forces 62
7.8 Interface analysis 63
7.9 Function integration 67
7.10 Designing machine elements and their interfaces 71
8. Mechanical fastening 73
8.1 Mechanical fastening theory 73
8.2 Connections and fastenings 77
8.3 Alternative connections and fastenings 82
8.4 Hose and cable connections 103
9. Positioning, setting and adjustment 105
9.1 Positioning vs. adjusting 105
9.2 Adjusting – the right way 108
9.3 Control 111
10. Organization 113
10.1 Organization of work steps 113
10.2 Environmental organization 125
11. Communication 133
11.1 Documentation 133
11.2 Before and after 134
12. Financial aspects 137
Quick changeover: Applying set-up reduction vii
12.1 Internal 137
12.2 External 139
13. Implementation examples 141
13.1 Press 142
13.2 Sheet bending line 145
13.3 Rollforming machine 148
Bibliography 151
Index 153
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Quick changeover: Applying set-up reduction ix
About the author
Karsten Herr has studied brewing technology and mechanical engineering.
He has worked for many years as an operations and production manager and
as a commissioning engineer. Since 2004, he has been working as a freelance
consulting engineer, training and coaching production companies. He supports
production companies of all sectors, in discrete as well as in continuous industries.
Projects on which he has worked range from complete production restructuring
via optimizing individual value streams to one-off training courses on different
topics on process and workplace organization.
Herr has specialized in the analysis of set-up procedures on machines and
processes and the drafting of quick changeover concepts. He regularly supports
companies with open and in-house workshops and analysis of set-ups and
drafting of solutions for quick changeovers as well as running improvement
projects of various scopes.
He also works as a lecturer at various universities and professional academies,
where he teaches courses on organization and structuring of business processes,
systems engineering and systems behavior, production organization and factory
planning, and production optimization. His main focus is on Lean, TOC, TPM,
QRM, and Six Sigma (Certified Black Belt).
Herr has a master’s degree in management and organization from the TiasNimbas
Business School, one of Europe’s top business schools.
