The Quick Changeover workshop is a two-day beginner level workshop that teaches participants techniques to radically reduce set-up times. Like most processes, machine set-ups and changeovers are riddled with waste. Removing this waste yields dramatically reduced set-up times thereby allowing for smaller batches and thus less inventory and reduced lead times.

During the Quick Changeover workshop, participants will learn about the principles of SMED (Single Minute Exchange of Dies) and will apply them to a machine within the organization. At the end of the two-day workshop, participants will have made measurable improvements to the machine's set-up time, and will have a list of other improvements for further reductions.

In addition to learning how to reduce changeover time, participants will learn why it is important to do so. The benefits of small batch production will be reviewed, and participants will learn how to calculate the proper batch size given customer demand and set-up time. These techniques will also be used to set a target for the quick changeover exercise. Many organizations begin a Quick Changeover exercise thinking that all changeovers must be reduced to the lowest time possible. Although this would be nice, there is usually some cost associated with reducing set-up times. By understanding how quickly you need to change from one product to another, much of this expense can be delayed until it is required.

Like most Lean Solutions workshops, Quick Changeover combines classroom theory with practical exercises and case study simulations to reinforce the training. A simple simulation will demonstrate the advantages of Quick Changeover. Workshop participants will then be assigned a machine within your facility to which the principles of Quick Changeover will be applied.

• Introduce Quick Changeover
• Learn how to calculate optimal batch size
• Introduce methods to reduce waste in the set-up process
• Implement Quick Changeover in a process within your facility

Day One

• Review of Lean Principles
• Introduction to the SMED system
• Work Element Identification

• Removal of Waste from the Changeover Process
• Standardization of the New Procedure
• Workshop Summary

Workshop participants will be able to apply the principles of Quick Changeover to any area of your organization. Typical results include a 50 - 80% reduction in changeover times with little or no investment within one week of completing the workshop.

This workshop is great for operators, managers, supervisors, team leaders, quality employees, engineers, and maintenance employees. An ideal team consists of a sample from each of these areas with more emphasis on maintenance personnel. Participation of employees that typically conduct the changeover is critical as their knowledge of the processes is essential. They will also be key in communicating the new methods to the rest of the production team.

Most attendees should have some prior Lean knowledge. If Lean is new to your organization, consider starting your Lean journey with either Launching the Lean Initiative or Lean Principles. Typically, Quick Changeover is applied based upon a need identified during the Value Stream Mapping process. If your organization has not yet completed a Future State Map and Implementation Plan, you may want to consider the Value Stream Mapping workshop prior to the Quick Changeover workshop. There are also several articles and books available on Lean and 5S which will give participants a good foundation. Check our website for articles and recommended readings.

Many companies that are considering Lean, but are not yet sold on the idea use the Quick Changeover workshop as a "taste test". By applying Quick Changeover to a single process, these organizations learn how Lean can dramatically improve their productivity, lead-time, quality, and many other key indicators.

As with all our workshops, each participant receives their own workshop binder so they can keep their own notes for reference once the workshop is over. Participants also receive a Certificate of Completion to show that they have completed a Lean Solutions workshop.

The materials from the workshop may be redistributed within the company. Many organizations choose to hold short training sessions using these materials prior to applying Quick Changeover to an area of the company so that all employees participating receive training on the principles of Quick Changeover. Additional workbooks are also available (call for pricing).

You also receive a 100% guarantee! If you are not satisfied either with the material covered or the teaching style of the workshop facilitator, there will be no charge! If we fail to meet your expectations, the only thing you will be asked to pay for will be the expenses incurred.

Although our workshops are designed to give the knowledge to you and your team, follow-up days are recommended to review progress made following each workshop. Typical organizations require one to two follow-up days about 2-4 weeks following the workshop. These follow-up days also help to ensure that the principles learned during the workshop are not forgotten or neglected after the workshop is over. If you are interested in a greater involvement by one of our expert facilitators, check out our On-Site Lean Implementation solution.

The base cost for this two-day workshop is $7,000, which covers the first 15 participants. Classes larger than 15 participants will be taught by two facilitators and cost $11,000. In order to keep the class size manageable and to facilitate the learning process, Lean Solutions restricts the maximum class size to 30 participants. Follow-up days cost $1,500-$2,000 per day, depending upon the experience of the facilitator. There is a 10% discount available for long-term engagements. Expenses are in addition to the costs outlined above and include cost of travel and accommodation (if required) as well as meals and workbooks ($20 per participant).

Lean Solutions will tailor workshops to meet each company's requirements. Call or e-mail for more information or to schedule a workshop.