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Keep Calm and Stop the Line—Part 2

Christoph Roser — Tue, 09 Jan 2024 11:00:04 +0000

In manufacturing, a common sentiment is that the line (or generally the process) must run. There is some truth to that, but—counterintuitively—for a system to run well you need to know when to stop it too. This is my second post in a series giving you an overview on when it may be better to ... Read more

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Ramp-Up and Ramp-Down of Production

Christoph Roser — Tue, 12 Sep 2023 11:00:30 +0000

In my last post I looked at the preparations for a proper ramp-up or start of a machine or process. This post is the second part where you actually press the button and start the machine. I will also discuss the ramp-down procedures, as well as a SMED-like approach to improve the ramp down and ... Read more

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Preparation for Ramp Up and Down of Production

Christoph Roser — Tue, 05 Sep 2023 11:00:30 +0000

Some factories work around the clock. But more commonly, factories ramp up at the beginning of the week, workday, or shift and then ramp down at the end. I often have the feeling that this is a somewhat neglected topic despite its influence on safety, quality, and efficiency. Hence I would like to take a ... Read more

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SMED 2.0—A Changeover for the Changeover

Christoph Roser — Tue, 25 Apr 2023 11:00:48 +0000

Single Minute Exchange of Die (SMED) to reduce and shorten changeover times is one of the best-known methods in lean manufacturing. However, the original steps as shown by Shingo have, in my view, potential for improvement. Hence, I restructured the changeover workshop based on my experience with SMED to make it easier and more straightforward. ... Read more

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A Few More Turns on the Changeover Wheel – Part 5: Frequently Asked Questions

Christoph Roser — Tue, 15 Mar 2022 11:00:48 +0000

In my last two posts I talked on how to set up a changeover wheel or, more generally, a changeover sequence. Next I will show you how to use a changeover wheel. The idea is simple, but there are some pitfalls as well as some tricks to make it easier. Let’s have a look. A ... Read more

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A Few More Turns on the Changeover Wheel – Part 4: Options for Prioritizing

Christoph Roser — Tue, 08 Mar 2022 11:00:12 +0000

In my last post of this series on the changeover wheel and changeover sequencing, I showed you the basics on how to use a changeover wheel or changeover sequence. In this post I will look at a few options and modifications that are sometimes used too. A Brief Recap We will continue the example from ... Read more

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A Few More Turns on the Changeover Wheel – Part 3: Prioritizing Jobs

Christoph Roser — Tue, 01 Mar 2022 11:00:18 +0000

In my last posts I talked on how to set up a changeover wheel or, more generally, a changeover sequence. Next I will show you how to use a changeover wheel. You have to fit you prioritized production into the sequence. The idea is simple, but there are some pitfalls as well as some tricks ... Read more

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A Few More Turns on the Changeover Wheel – Part 2: Improving the Sequence

Christoph Roser — Tue, 22 Feb 2022 11:00:35 +0000

In my last post I looked at how to create a changeover sequence. However, this was only the first draft of such a sequence. For a truly good sequence, you need to spend some more time optimizing the sequence. Try to get a better sequence, even though it is impossible to find the perfect solution ... Read more

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