“You can observe a lot just by watching”

Yogi Berra

One of the foundational Lean tools is QCO (quick changeover), which is also sometimes referred to as SMED (single minute exchange of die).  SMED includes a set of techniques that make it possible to perform equipment set-up and changeover operations in less than 10 minutes.  Not every changeover can be completed in this amount of time.  However, any operation would benefit from using this Lean tool if there is a requirement for:

• a change in “lot” types
• a process or set-up change

For this discussion, I will use the term QCO as being interchangeable with SMED. Most of the time, the opportunity for implementing QCO in a process is driven by the need for greater flexibility, quicker delivery, better quality, or higher productivity.  These are indeed significant benefits that are realized –  because this approach identifies and removes some of the eight sources of waste.  But there is an equally significant benefit to assessing a process and implementing QCO: the resulting process changes often make setups simpler & easier – and therefore faster and safer. The following case studies demonstrate how using QCO principles can lead to work which is not only completed in less time, but is also safer. Continue Reading