a5c-ai 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
- Document current state (video)
- Separate internal/external
- Convert internal to external
- Streamline internal setup
- Streamline external setup
- Standardize and train
- Track and improve
Integration Points
- Production scheduling systems
- Video analysis tools
- Training platforms
- OEE tracking systems