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It involves arranging needed items in such a way that they are easy to use and label them so that it can be easily found and put away. Implementing set in order prevents waste of motion, searching, human energy, excess inventory, defective products and unsafe conditions.

This involves regular cleaning up to ensure that the workplace is brought back to proper order at the end of each day. This helps in creating a workplace where people enjoy working. Problems avoided by implementing shine are as follows:

Single Minute Exchange of Dies (SMED) is the approach to reduce output and quality losses due to changeovers. The phrase “single minute” means that all changeovers and startups should take less than ten minutes.

Quick Changeover (QCO) eliminates or reduces non-value added activities in the setup and teardown processes of manufacturing, allowing companies to quickly and efficiently change from one product to another.

(1) In Preliminary Stage, internal and external setup is not differentiated. Internal setup can be performed only when machine is shut down and includes activities like fixing an attachment to machinery. External setup can be done while the machine is still running. It includes activities such as preparation and transfer of dies.

(3) In Stage 2, internal setup is converted to external setup. …

This allows an organization to sustain its 5S program by ensuring that 5S becomes part of the company culture.

(c) Why is 5S usually one of the first improvement activities a company undertakes on the journey towards “World Class”

5S is the key to world class performance because it is all about creating a more effective workplace that is well organized, free of clutter, and organized so that it provides the following benefits:

Improved quality with zero defects

Decreased cost through reduced waste

Improved delivery through less production delays and downtime

Increased morale because of cleaner, healthier workplace

Increased safety

(3) (a) What, exactly, is meant by the term Single Minute Exchange of Dies (SMED)

Single Minute Exchange of Dies (SMED) is the approach to reduce output and quality losses due to changeovers. The phrase “single minute” means that all changeovers and startups should take less than ten minutes.

(b) Another popular name for SMED is QCO. What is meant by the term “QCO”

Quick Changeover (QCO) eliminates or reduces non-value added activities in the setup and teardown processes of manufacturing, allowing companies to quickly and efficiently change from one product to another.

(c) Describe a 4 step procedure that could help a process or company achieve QCO

(1) In Preliminary Stage, internal and external setup is not differentiated. Internal setup can be performed only when machine is shut down and includes activities like fixing an attachment to machinery. External setup can be done while the machine is still running. It includes activities such as preparation and transfer of dies.