p>Many companies try to reduce Make Ready time utilizing teams of employees.
Much of our work involves training and working with these teams to achieve make
ready time reduction. The problem is teams typically take a long time to get
substantial improvements and they don't sustain the effort long enough to
achieve 90% reductions in make ready time. Usually the make ready time reduction
effort simply fades away with little more than 50% reductions in make ready on
some machines. Most companies need rapid make readies which equates to more than
a 90% reduction in make ready time on many machines. Because of this, we knew
there was a need for a different approach to reducing make ready time.
We have developed the FasTrack 8 step method. We analyze your current make
ready, provide the recommended improvements, get buy in from employees and fully
implement the improvement. You, the customer, are in control every step of the
way. You are provided complete documentation of recommendations and results to
expect and must approve before implementation. If you choose, Claunch &
Associates, Inc. can make the recommendations and you can have your employees
implement.
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We conduct an assessment to determine the minimum
amount of improvement that is possible in your make ready
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We document your current make ready
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We analyze your current make ready and develop our
recommended improvements.
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We review our recommended improvements, including
costs to implement, with management.
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We review our recommended improvements with your shop
experts. (i.e. supervision, make ready experts, operators, and engineers.)
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Once you give the go ahead, we implement the
improvements and verify the results.
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We determine the most productive sequence of make
ready steps and document the new make ready procedure.
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We train all applicable employees in the new make
ready procedure.
Typically these 8 steps break down into three phases.
- We come to your facility to conduct an assessment to determine the
minimum amount of improvement that is possible in your make readies.
First we examine your current make ready documentation, historical data,
interview your changeover experts. Then we video tape a normal make
ready completed by your best make ready expert including start up.
Finally, we meet with management to present our initial determination of the
amount of improvement we believe is possible.
- We document your current make ready. Utilizing the
video tape we took, we now identify the elements of your current make ready,
and load it into our make ready time reduction software.
- We analyze your current make ready and document our recommended
improvements. Every element of your current make ready and
startup is examined to determine what low cost improvements can be made,
including a bill of materials to be purchased and the specific amount of
time that can be reduced.
Phase 1 Objective: Identify current make ready elements and
recommended improvements.
Phase 1 Deliverables:
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We review our recommended improvements,
including costs to implement, with management. Typically the
review with management is involved more with the resulting reduction in make
ready time and the cost to implement. Once you give the go ahead, we then
conduct a review with the make ready experts.
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We review our recommended improvements with your
shop experts. (i.e. supervision, make ready experts, operators, engineers
and management.) This review session is very detailed and is
supported with our make ready documentation, implementation planner, video
tape, pictures of improvement and catalogs of purchased items.
Phase 2 Objective: Review sessions wherein each recommendation is
presented for buy in and improvement as necessary.
Phase 2 Deliverables:
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Meeting with management and supervision.
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Meeting with operators and mechanics.
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Final implementation planner including all
improvements, costs and time reduced.
Our guarantee: "If Claunch & Associates, Inc. can not identify
improvements that result in at least a 50% reduction in make ready time, based
on the make ready they document at your facility, you pay nothing for their
services, no matter how much time or costs they have incurred on your
behalf."
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Once you give the go ahead, we implement the
improvements and verify the results. We order all necessary
materials, fabricate and implement all the improvements approved in step 5.
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We determine the most productive sequence of
make ready steps and document the new make ready procedure.
Once all improvements are implemented, we work on the sequence of the
remaining changeover steps and develop a make ready manual for your plant.
We determine what the most efficient sequence is and layout the manual in
that order, including pictures and descriptions of each step, and a
checklist of the changeover steps.
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We train all applicable employees in the new
make ready procedure. Every employee who would do a make ready
is trained by Claunch & Associates in the improved method. Both the
trainer and the employee must sign off that they are capable of doing a make
ready on their own.
Phase 3 Objective: Provide a turnkey implementation.
Phase 3 Deliverables:
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Complete implementation on machine make ready
improvement.
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Make ready procedure manual.
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Training of employees doing make readies.
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Make ready checklist
SPECIAL BONUS: Baseline Settings Manual
We at Claunch & Associates, Inc. have found that often after we leave,
adjustments are sometimes made by employees that reverse the improvements.
Because of this, we will include a baseline settings manual for each machine we
implement the make ready time reduction. This manual will provide all the
settings that we determine are critical to a reliable startup. In the event of a
poor start up, your employees can go back to this manual and determine what
settings have been changed and reset those to the proper setting. Ensuring that
all employees that may adjust settings utilizing the information in this manual
will ensure you always have Rapid make readies and Reliable startups.
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