Changeover Optimizer

Overview

The Changeover Optimizer skill provides comprehensive capabilities for reducing setup and changeover times. It supports SMED (Single-Minute Exchange of Die) methodology, sequence optimization, and changeover time tracking.

Capabilities

• Internal/external setup separation
• Changeover video analysis
• Parallel task identification
• Standardization opportunities
• Quick-release mechanisms
• Sequence optimization
• Changeover matrix
• Time reduction tracking

Used By Processes

• LEAN-004: Kanban System Design
• CAP-002: Production Scheduling Optimization
• LEAN-003: Kaizen Event Facilitation

Tools and Libraries

• Video analysis tools
• SMED templates
• Time study software
• Scheduling optimization

Usage

skill: changeover-optimizer
inputs:
  equipment: "Injection Molding Press 5"
  current_changeover_time: 120  # minutes
  target_changeover_time: 30
  changeover_data:
    video_analysis: "changeover_video_url"
    task_breakdown:
      - task: "Remove old mold"
        time: 15
        type: "internal"
      - task: "Get new mold from storage"
        time: 20
        type: "internal"
      - task: "Install new mold"
        time: 25
        type: "internal"
      - task: "Connect utilities"
        time: 15
        type: "internal"
      - task: "Adjust parameters"
        time: 25
        type: "internal"
      - task: "Run test shots"
        time: 20
        type: "internal"
outputs:
  - current_state_analysis
  - internal_external_separation
  - improvement_opportunities
  - optimized_procedure
  - changeover_matrix
  - implementation_plan

SMED Methodology

Stage 1: Separate Internal and External Setup

Type	Definition	Goal
Internal	Must stop machine	Minimize
External	Machine running	Maximize

Stage 2: Convert Internal to External

• Pre-stage tools and materials
• Pre-heat/pre-cool components
• Prepare documentation
• Pre-adjust settings

Stage 3: Streamline All Operations

• Parallel tasks (multiple operators)
• Eliminate adjustments
• Standardize procedures
• Use quick-release mechanisms

Changeover Analysis

Current State:
- Total time: 120 minutes
- Internal: 100 minutes
- External: 20 minutes

Improvement Opportunities:
1. Move mold retrieval to external: -20 min
2. Pre-heat mold: -10 min
3. Use quick-clamps: -15 min
4. Parallel connection work: -10 min
5. Eliminate test shots: -15 min

Target State:
- Total time: 30 minutes
- Internal: 25 minutes
- External: 35 minutes

Changeover Matrix

From / To	Product A	Product B	Product C
Product A	-	30 min	45 min
Product B	35 min	-	25 min
Product C	40 min	30 min	-

Quick Changeover Techniques

Technique	Application
Quick-release clamps	Replace bolts
Intermediate jigs	Pre-positioned tooling
Color coding	Visual identification
One-turn fasteners	Reduce turns required
Standardized heights	Eliminate adjustments
Preset gauges	Eliminate measurement

Implementation Steps

1. Document current state (video)
2. Separate internal/external
3. Convert internal to external
4. Streamline internal setup
5. Streamline external setup
6. Standardize and train
7. Track and improve

Integration Points

• Production scheduling systems
• Video analysis tools
• Training platforms
• OEE tracking systems