quick changeovers

Reduce Changeover Times

Lean Expert Training Online

Welcome to lesson seven in the Level 3 – Lean Expert Training Course.

To see detailed instructions explaining how to watch the videos and download any attached files or documents for this lesson…click here.


Lesson 307 – Step 5 Reduce Changeover Times

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In the Level 2 – Lean Practitioner training course you learned how Step 5 – Reduce Changeover Times is focused on the identification and elimination of process downtime.  You learned that the number one cause of process downtime are changeovers or set-ups that force the operation to stop and start up again. You also learned that one minute of downtime is equal one minute of lost production time!

In the Level 3 – Lean Expert training course, you will learn about the detailed application and integration of Step 5 – Reduce Changeover Times as part of a continuous process improvement methodology.

Transformation requires a plan and an infrastructure that is focused on waste reduction to improve value for the customer. It also requires a strong management team that is willing to support the process because the right kind of change does not happen by chance!

In Step 4 – Improve Process Flow, you recognized process constraints that impeded the flow. In this next step, you will learn how to identify the elements of downtime and help  reduce the impact of one of the major constraints to speed up the process flow.


Lesson 307-1: Introduction to Step 5 Reduce Changeover Times (4:37) In this introduction video, Chris Turner gives an overview of the Level 3 – Lean Expert Step 5 Reduce Changeover Times training materials, and he explains why they are integral part of  the 10 Step training and implementation process – 

Lesson 307-2: Step 5 Reduce Changeover Times Part 1 (22:54) – 
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To download the documents for Step 5 Part 1…click here

Lesson 307-3: Step 5 Reduce Changeover Times Part 2 (16:43) – 
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To download the documents for Step 5 Part 2…click here

Lesson 307-4: Step 5 Reduce Changeover Times Part 3 (11:51) – 
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To download the documents for Step 5 Part 3…click here

Lesson 307-5: Step 5 Reduce Changeover Times Part 4 (16:35) – 
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To download the documents for Step 5 Part 4…click here

Lesson 307-6: Step 5 Reduce Changeover Times Part 5 (20:56) – 
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To download the documents for Step 5 Part 5…click here

Lesson 307 – Additional Learning Resources

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Throughout the Lean Expert course we try to share relevant information that gives a practical example of the application of the lean tools and techniques presented in the training materials.

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Video 1: In this video, Phil Koeher, Manufacturing Productivity Business Development Manager, Iconics Inc. discusses OEE to achieve operational efficiency (25:50) – [video_lightbox_youtube video_id=RDso8Ym38WE&feature=relmfu width=640 height=480 anchor= “Click here to view video”]

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Video 2: In this video clip from Setpoint Systems, you can see some practical examples of lean principles, especially Quick Changeovers (3:01) – [video_lightbox_youtube video_id=lGl-aEu0H_Q&feature=relmfu width=640 height=480 anchor= “Click here to view video”]

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Video 3: In this video clip from Automated Learning there are some great examples of changeover improvements, many of which we take for granted (3:29) – [video_lightbox_youtube video_id=KySTwvVnZ0Q&feature=relmfu width=640 height=480 anchor= “Click here to view video”]

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Video 4: In this video clip from Lean Games you can see an example of a changeover simulation used to teach employees about SMED or changeover improvements (2:40) – [video_lightbox_youtube video_id=wKKIlof0rzw&feature=relmfu width=640 height=480 anchor= “Click here to view video”]

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Video 5: In this video clip from Premitec, you can see a practical example of a quick die change using air operated lifters (0:36) – [video_lightbox_youtube video_id=myLwPeoIgmU&feature=relmfu width=640 height=480 anchor= “Click here to view video”]

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Video 6: In this video clip, you can see a practical example of a Forwell’s QDCS Quick Die Change System (5:34) – [video_lightbox_youtube video_id=sqEvTK5Y9QI&feature=relmfu width=640 height=480 anchor= “Click here to view video”]


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