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1、Quick Changeover Overview 快速切换概述快速切换概述JCMS UniversityLevel 101 Core ConceptsQUICK CHANGEOVER OVERVIEWCOCourse Objectives 课程目标课程目标uRelate Quick Changeover(QCO)to level production.u 将快速改革（QCO）与水平生产联系起来uDescribe the differences between internal and external changeover time.u描述内部与外部制度改革时间的差异uIdentify th
2、e eight stages of Quick Changeover(per process poster).u确认快速改革的八个步骤（每个步骤的海报）2QCO WSP-6/25/03QUICK CHANGEOVER OVERVIEWCODefinition 定义定义uQuick Changeover is a structured process that:u快速改革是个结构过程用来Reduces waste 减少浪费Shortens lead times 减少时间Improves manufacturing capacity,flexibility,and quality 提高生产能力,灵
3、活性和质量.uThe goal is to reduce the time from“last good piece”to“first good piece,”down to customer takt time.目标把从“最后一个好的零件”到“第一个好的零件”的时间减少至客户的takt时间3QCO WSP-6/25/03QUICK CHANGEOVER OVERVIEWCOTerms 术语术语uQuick Changeover utilizes SMED(single minute exchange of dies)philosophy to achieve this.u快速改革利用SMED
4、(硬模的单个分钟交换)理论来实现uOther terms associated with QCO include:u与QCO有关的其他术语包括:Setup Reduction 结构缩减Quick Die Change 快速硬模改变Quick Mold Change 快速铸模改变Cycle Time Reduction 降低循环时间4QCO WSP-6/25/03QUICK CHANGEOVER OVERVIEWCOScope 范围范围uQuick changeover applies to any machine in any part of the business that has mor
5、e than one job.u快速改革可应用在任何适用于各种商业方面的机器uIt is easiest to apply in batch operations such as stamping,but welding,assembly,conveyors and office equipment can also benefit.u快速改革应用在成批运作如冲压中比较简单，然而焊接，组装，运输和办公设备也可从中获益。5QCO WSP-6/25/03QUICK CHANGEOVER OVERVIEWCOJCMS Philosophy JCMS理念理念Zero Tolerance for Was
6、te 决不浪费决不浪费 Stable Production Environment 稳定生产环境稳定生产环境Customer“Pull”Drives Production 客户需求拉动生产客户需求拉动生产6QCO WSP-6/25/03QUICK CHANGEOVER OVERVIEWCOQuick Changeover Supports 快速改革支持快速改革支持uQCO reduces the following wastes associated with changeover:u快速改革降低以下与改革有关的浪费Transportation 运输Inventory 库存Motion 移动W
7、aiting 等待uIn concert with Total Productive Maintenance and 5S,QCO reduces setup time to the lowest level(Customer takt time).u与完全生产保养和5s一致,快速改革把起步时间减小到最低.(客户takt时间)Zero Tolerance for Waste决不浪费决不浪费7QCO WSP-6/25/03QUICK CHANGEOVER OVERVIEWCOQuick Changeover SupportsuQCO improves the repeatability of c
8、hangeover operations.u快速改革提高改革运作的可重复率uQCO generates confidence that a process will be producing quality parts within“X”minutes of changeover.u快速改革引起相信在“X”分钟的改革内生产质量高的零件的信心uQCO makes it possible to go to“leveled production.”u快速改革使达到稳定的生产成为可能Stable Production Environment决不浪费决不浪费8QCO WSP-6/25/03QUICK C
9、HANGEOVER OVERVIEWCOLeveled Production 稳定的生产稳定的生产ProductDemand/MonthProduction TimelineOne MonthA100B200C300One MonthLot ProductionProductDemand/Half MonthProduction TimelineOne MonthA50B100C150Half MonthLot Production(Smaller Lots)Produce the entire demand for the month in one lotProduce more than
10、once per month-smaller lots9QCO WSP-6/25/03QUICK CHANGEOVER OVERVIEWCOQuick Changeover Supports快速改革支持快速改革支持uQuicker changeover means increased flexibility to handle sudden changes in customer demand.u快速改革意味着提高灵活性来应付客户要求的突然改变uLot sizes and inventory levels can be reduced with no impact on utilization
11、.u批量大小和库存大小可在对应用无影响的情况下减小.uQCO supports“one piece flow”philosophy-the most flexible system available.u快速改革支持“一次流通”理念-现有的最灵活的系统Customer“Pull”Drives Production客户需求拉动生产客户需求拉动生产10QCO WSP-6/25/03QUICK CHANGEOVER OVERVIEWCOWaste In Changeover Operations在改革运作中的浪费在改革运作中的浪费Waste inChangeover OperationsWaste
12、inExternalChangeover PreparationWasteWaiting&MotionTransportationCleanup WasteTransportationMotionReplacementWasteTransportationOver ProcessingAdjustmentWasteTransportationCorrectionWaste inInternalChangeover Internal Changeover TimeChangeover Time=+External Changeover Time11QCO WSP-6/25/03QUICK CHA
13、NGEOVER OVERVIEWCODefinitions 定义定义uInternal Changeover Time 内部改革时间Begins when the last good part comes off the current run开始当最后一个好的零件出现在本轮中Ends when the first good(defect free)piece comes off the next run.结束当第一个好的(没有毛病的)零件出现在下一轮中Sometimes referred to as“last good to first good”.从最后一个好的到下一个好的中的时间Duri
14、ng internal changeover time,the machine adds no value to the work piece.在内部改革时间中,机器对工作部分没有增加值uExternal Changeover Time 外部改革时间The time spent by an operator carrying out setup procedures for the next run,independent of the machine,while the machine is operating.操作者实行为下一轮的起步步骤的时间.与运作的机器无关.12QCO WSP-6/2
15、5/03QUICK CHANGEOVER OVERVIEWCOQCO Goals 快速改革目标快速改革目标Convert Internal to External changeover time.从内部向外部改革时间转变Reduce or eliminate External changeover time.减少或消除外部改革时间1213QCO WSP-6/25/03QUICK CHANGEOVER OVERVIEWCOQCO Improvement Process快速改革改善过程快速改革改善过程External Setup(Process is Running)Internal Setup(
16、Process is Down)Change from Internal to ExternalImplement JigsEliminate AdjustmentImprove Internal SetupMechanical ImprovementsParallel OperationsStandardization234576Meet GoalSeparate Internaland External1814QCO WSP-6/25/03QUICK CHANGEOVER OVERVIEWCOQCO Review QCO回顾回顾uHow does quick changeover rela
17、te to leveled production?u快速改革如何与稳定生产有关?uWhat is the difference between internal and external changeover time?u内部改革和外部改革时间有何区别?uWhat are the eight stages of quick changeover?u快速改革的八个阶段是什么?15QCO WSP-6/25/03QUICK CHANGEOVER OVERVIEWCOQCO Application QCO附加材料附加材料uUnderstand/be able to explain the Quick
18、Changeover process poster.u理解/解释快速改革过程海报uPick a machine or process and挑选一个机器或流水线然后Identify external changeover steps.确定外部改变步骤Identify internal changeover steps.确定内部改变步骤Identify any actions to convert internal to external.确定从内部向外部改变的任何行动Identify any actions to reduce waster in the changeover process.
19、确定在改变过程中减少浪费的任何行动16QCO WSP-6/25/03QUICK CHANGEOVER OVERVIEWCOAdditional Resources 附加材料来源附加材料来源uQuick Changeover Curriculum:快速改革课程Quick Changeover Overview:30 minutes快速改革概述:30分钟Quick Changeover Event:8-16 hours快速改革项目:8-16小时uBOS Documents:BOS文件JCMS Assessment(WW-MOS-CL-09-01)JCMS评估(WW-MOS-CL-09-01)uFocus on Performance:工作中心View the Focus Course Catalog and sign up for JCMS classes via the Leadership Institute website.通过领导学社网址查看中心课程目录并参加JCMS课程17QCO WSP-6/25/03