Quick Changeover (SMED) at the Lean Donut Shop
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- Опубліковано 24 тра 2021
- See how to reduce changeover and setup times by applying SMED (single minute exchange of die) aka "quick changeover" practices. We demonstrate the before and after result of applying SMED/quick changeover at the Lean Donut Shop.
You must know how to shorten changeover times in order to overcome the TWO major problems associated with lengthy changeovers:
1. Lost equipment capacity
2. Over production and big batching
A quick changeover makes your production system more flexible and nimble. You can increase the mix of product without sacrificing equipment capacity.
Learn more about SMED and quick changeovers in our courses at the Lean Smarts Academy:
1. Kaizen Best Practices (leansmarts.com/courses/kaizen...)
2. The Fundamentals of Lean (leansmarts.com/courses/fundam...)
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As an Industrial Engineer, I find your videos a lot helpful. I had just randomly discovered your channel 3 years ago when I was under study, since then, I have become a fan of yours.
excellent work buddy! keep it up. Request you to being more free content rather than paid courses. We need FREEEEEE. Thanks
Welcome back! I haven’t seen a video from you in forever!
Love your videos, and the real world application with your family's small business. This one reminded me of The Goal, when the foreman at the heat treat oven came up with the idea of setting up a batch, while waiting for a batch to come out of the oven.
Assuming the fryer is the bottleneck, and every donut fried can be sold, then as long as total number of sellable donuts is increased per hour, it's likely a win. Given every other batch is 8 donuts, vs 9 donuts, the 17.4 batches per hour translates to 8.7 batches of 8, and 8.7 batches of 9. That's 69.6 + 78.3 = 147.9 donuts per hour. Compared to the original time of 255 seconds per batch and 14.1 batches of 9 donuts (aka 127 donuts), the new process should result in an increase of 27 donuts. Multiply that by the per-donut sales revenue, and we can see the increase in revenue.
However, a couple of things may reduce this 27-donut revenue increase.
Was the original changeover process's time artificially increased to 55 seconds by hand-removing each donut from the fryer basket and placing it precisely on the rack? The second time through, the 9 donuts were dumped out onto the rack. If dumping them out was okay, it should have been done that way the first time.
Will the alternating two basket/one basket process require a different process every other time? If yes, we'd want to know the cycle time for each. For example: One large basket can be held up while slipping each of the smaller two underneath it. Will that work when putting the large basket under the two smaller ones? If the two small baskets need to be removed and set elsewhere while the big one is picked up and loaded in the oil, then space needs and worker motion are increased.
Finally, increasing the number of batches per hour means the oil will need to be replaced more often. That setup time and expense should also be factored in.
Good insights!
Good video, though this is an example of a reduction in cycle time, not changeover time. A changeover would be the case of, for instance, a change in frying oil or frying temperature, as for a change in product
the actual cycles/hr after is 11.5 not 17.4 (207/18=11.5) ! im i right ?
Cycles per hour
= 3600s in an hr / (200s cook time + 7s change time)
= 3600 / 207
= 17.4
How to calculate fryer efficiency ?
100% efficiency would be the 18 cycles per hour.
The before efficiency of 78% was calculated, taking 14.1/18 which equals .7833. Multiply .7833 by 100 to make it 78.33 which is the percentage of efficiency rounded down to 78%.
It's the same process to find the after efficiency percentage of 96.66% rounded up to 97%.
Hope this helps.