Quick Changeover Examples (SMED)

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Angelina Hampton
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1 Quick Changeover Examples (SMED) AMF Process Improvement Group 16 February

2 Remember the Basics Ø OBSERVE the process Ø IDENTIFY steps that NEED to be done whilst stopped and what CAN be done whilst it s running Ø MOVE INT to EXT Ø OPTIMISE Shorten INT Ø OPTIMISE Shorten EXT Slide 2

Forced to sell 1 of its planes within 24mths The answer: Unload and load passengers

3 Services Southwest Airlines Early 1970 s startup called Southwest Airlines posted loss of $1.6m. Forced to sell 1 of its planes within 24mths The answer: Unload and load passengers faster than any other airline and get planes back in the air The 10 minute Turnaround The following year SA posted its first profit and stayed black since Slide 3

Alight Clean Reload/ Seating Checks Push back Taxi Takeoff Identified

4 Southwest How did they do it? ruthlessly applied the principles Land Park at gate Retrieve luggage Alight Clean Reload/ Seating Checks Push back Taxi Takeoff Identified External steps Land Park at gate Retrieve luggage Alight Clean Reload/ Seating Checks Push back Taxi Takeoff Slide 4

5 Southwest How did they do it? Moved INT to EXT Looked for parallel work opportunities Checks Takeoff Push back Taxi Retrieve luggage Clean Reload/ Seating Land Park at gate Alight Slide 5

6 Southwest How did they do it? Before and after Land Park at gate Retrieve luggage Alight Clean Reload/ Seating Checks Push back Taxi Takeoff process time Push back Checks Taxi Takeoff Reduction in turnaround (process lead time) Reduced costs Competitive edge Retrieve luggage Clean Reload/ Seating Land Park at gate Alight Slide 6

7 Applying the Principles 1. Single Minute Exchange of People 2. Single Minute Exchange of Aircraft Used same aircraft (versus 10 at competitors) Ø Interchangeability (aircraft and components) Ø Simplified mechanics training and skill set Ø Lower spares inventory Ø Same size/shape for gate access Point to Point Operation Ø Less congestion than at Hubs (slot availability and volatility) Ø Less impact of weather Don t charge customers for bags Slide 7

8 How Fast Can You Change a Tyre? What are the obvious steps they made EXTERNAL Slide 8

9 Manufacturing Quick Changeover Die alignment tolerances on dowels with chamfers Automated coating process in cabinet whilst preparing machine Moved inspection to External Standardized warm-up process Reduced the need to fetch documentation Inside operation Stopped continual tampering with dies made them compliant Slide 9

10 Manufacturing/Assembly Quick Changeover Same principles and questions need to be asked Involve process workers Examples: Indexed assembly carousels Implement parallel activities Quick release clamping, or boltless clamping methods Snap-on hose connectors Positive location methods (eliminate adjustments) Multiple entry points to machine/assembly jigs Etc. Slide 10

11 Benefits Less downtime Less inventory (smaller batches) Quicker turnaround (responsiveness) Better delivery performance Reduced costs Easier for employees Slide 11

12 Summary and Health Warnings SMED (Quick changeover) improves productivity for a particular type of problem Other lean improvement techniques improve productivity, reduce costs and improve quality Tips: Involve process users (video if possible) Focus on the right problematic areas not FOTM Standardization codify not tacit Don t take away the examples as templates take away the principles Your application will be unique, but relevant Slide 12

13 Gavin Jones Slide 13

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