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The Quick Changeover Playbook
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Complete with color pictures from real quick changeover implementations, The Quick Changeover Playbook provides detailed step-by-step guidelines on how to reduce setup times as well as improve flexibility, product quality, and visual control while reducing lead times and costs. This new book in The LEAN Playbook Series is your guide to effective setup-reduction projects. It is ideal for Lean practitioners and facilitators seeking a training tool and a guideline that can be used in the work area while improvements are being made. Like a football coach, you can use this playbook for quick reference to convey what's needed to facilitate quick changeovers. If for some reason you forget a "play" during the implementation, you can easily reference the playbook. You can follow page by page, or you can go directly to certain topics and use it to help you implement that particular "play." In addition to color pictures from quick changeover implementations, a combination of short paragraphs and bulleted descriptions walk you through how to effectively reduce setup times on equipment. Wasting little time on high-level theory, the book includes an introductory section dedicated to the 8 Wastes and Lean metrics to provide you with the foundation required to fully benefit from this playbook. The book covers the key concepts you must understand to reduce setup times, including the four steps of a setup, data collection, internal and external work, one-turn methods, intermediate tooling, and standard work. Looking for supplemental information or Lean coaching from Chris Ortiz? Go to www.leanplaybooks.com to receive ongoing support and advice on how to use The LEAN Playbook Series for training and implementation.
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Table of Contents

Setup and Quick Changeover Introduction Preparation Removing and Mounting Components in Machine (Changeover) Measurements Trial Runs and Final Adjustments Four Setup Steps External and Internal Setup Steps Data Collection Introduction Time Studies Spaghetti Diagrams 5S and Layout Improvements Introduction End-of-Day Cleanup Procedure Daily Walkthrough 5S Audit Form/Criteria 5S Tracking Sheet Intermediate Tooling and One-Turn Methods Intermediate Tooling Visual Management Introduction Startup Boards Work Instructions Production Control Boards After Improvements Impact on Cycle Time Low and Infrequent Use Conclusion Definition of Terms Index

About the Author

Chris Ortiz is the founder of Kaizen Assembly, a Lean manufacturing training and implementation firm in Bellingham, Washington. Chris has been featured on CNN Headline News on Inside Business with Fred Thompson. He is the author of multiple books on Lean manufacturing. Chris Ortiz is a frequent presenter and keynote speaker at conferences around North America. He has also been interviewed on KGMI radio and the American Innovator and has written numerous articles on Lean manufacturing and business improvement for various regional and national publications. Kaizen Assembly's clients include industry leaders in aerospace, composites, processing, automotive, rope-manufacturing, restoration equipment, food-processing, and fish-processing industries. Chris Ortiz is considered an expert in the field in Lean manufacturing implementation and has over 15 years of experience in his field of expertise.

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