Abstract:
Quick Changeover (QCO)
Gain productivity with a low
cost solution by applying Quick Changeover (QCO) techniques to your machines
and equipment. Studied and revolutionized by Shigeo Shingo in the 1960s, and
described as “Single
Minute Exchange of Dies” or SMED, Toyota was able to combine QCO and
smaller batch sizes to vastly improve Just-in-time manufacturing. The
concept behind QCO is to reduce the amount of time a machine is down during
a changeover and to get it up and running making good parts as quickly as
possible.
Set up time reduction (QCO)
projects are performed as Kaizen Events. The “Eight week” Kaizen with prior
robust planning, a four (or five) day Kaizen event itself, plus the 30-day
follow-up works best for standardizing at the
improved level and for sustaining the
“gains”.
This four-hour workshop will describe how to implement an Eight week
Kaizen.
The importance of teamwork,
cultural change, preparation & communication, brainstorming ideas, “stretch”
goal-setting,
“internal”
vs. “external” task analysis, aligning
personal goals and converting the new way of setting up into “daily
work”, senior management support, etc. for the success of any QCO/SMED
project will be explained.
Total Productive Maintenance
(TPM) and 5S
This part of the class will
cover the basics of Total Productive Maintenance and introduce steps needed
for TPM Preparation and Implementation.
This session includes classroom exercises and case studies to cover key
topics including: critical equipment, Autonomous Maintenance, Planned
Maintenance (e.g., Preventive Maintenance, Predictive Maintenance, and
Maintenance Prevention) and Overall Equipment Effectiveness (OEE).
5S is
about workplace organization, teamwork, building discipline and reducing
waste. It is commonly referred to as:
Sort, Set-in-Order, Shine, Standardize,
and Sustain. The power of 5S comes from removing items not needed in the
immediate workspace and organizing the items that do belong.
About the Speaker:
Tony Manos is a Catalyst
with Profero, Inc., where he provides professional consulting services to
organizations focusing on implementing Lean. Mr. Manos has extensive
knowledge of Lean and quality in a wide range of work
environments including manufacturing,
office, support functions, service and healthcare. Tony is an
internationally recognized speaker and expert on Lean including Value
Stream Mapping and other topics. 
Tony
is the co-author of the book “Lean Kaizen: A Simplified Approach to Process
Improvement” and author of many articles on Lean and its allied subjects.
As a member of American
Society for Quality’s (ASQ) faculty, he teaches a two-day course in Lean
Enterprise and a one-day course on Lean Kaizen. He also teaches a course on
Lean Supply Chain for the Purchasing Management Association of Canada. Tony
is the past Chair of the Lean Enterprise Division of ASQ. He is a senior
member of the Society of Manufacturing Engineers (SME), a member of the
Association for Manufacturing Excellence (AME) and is also a Shingo Prize
Examiner for Manufacturing Excellence.
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