Situation in production
Changeover to the next part
Tools, programs and settings are changed. When is the first part approved?
What happens
The machine is changed over from one part to the next. Tools, programs and settings are changed.
What should apply
The changeover should take the planned time, and the first parts after the changeover should be approved before production starts.
Why it is difficult
- Different people do the steps differently.
- It is unclear when the first-piece inspection is approved and production can start.
- Changeover time is rarely shown separately from other stops.
The context that is needed
- Checklist or instruction for the changeover
- The result of the first-piece inspection
- Earlier changeovers for the same part
- How long the changeover took
When may production start after a changeover?
Illustration · Example dataThe checklist makes the steps the same every time and shows what remains. What decides the start is the first-piece inspection: production is released only when the first parts are approved against the tolerance.
Step by step
- The changeover checklist: tool changed, program loaded, material checked and gauge ready are done. What remains is to measure the first part.
- The first-piece inspection: length, diameter and height are measured and are all within tolerance.
- Decision: the part is approved, production starts and the inspection is saved with order and time. If a characteristic had been outside, the machine would have been adjusted and a new part measured.
Same situation, different questions
Who needs to know what
The same event looks different depending on which decision you have to make.
The same evidence for everyone
- Checklist or instruction for the changeover
- The result of the first-piece inspection
- Earlier changeovers for the same part
- How long the changeover took
Asks
"Is everything done, and is the first part approved?"
Decides
Whether production can start.
Asks
"Has the first-piece inspection been done and documented?"
Decides
Whether production may be released.
Asks
"How long do changeovers take, and where does the time go?"
Decides
Which changeovers to improve.
What may follow
- 01Follow the checklist
- 02Do and record the first-piece inspection
- 03Start production
- 04Shorten the changeovers that take too long
Knowledge
Concepts that help
Where Rektron can help
What is available today
Eyesight has first-piece and last-piece inspection. Digital checklists can be used for routines such as changeover.
Common in: Plastics and injection moulding
Similar situations
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