A formal design for changeover methodology. Part 1: theory and background

A rapid changeover capability is central to today's thinking in respect of responsive, small batch manufacturing. Mass customization and other modern manufacturing paradigms have prompted companies to adapt swiftly to market turbulence and at the same time avoid the traditionally high unit costs associated with custom-made or small-volume products. Historically, an operation-focused approach has been adopted in reducing changeover times; however, it is argued that there is a significant benefit if there is a focus on equipment design. There is a considerable challenge to design and build cost-effective changeover-capable equipment. This challenge would be greatly assisted by the availability of a coherent design for changeover (DFC) methodology. The authors have been researching the changeover area for many years and present their latest thinking in two parts. In the first part of this paper the basic concepts for a formal DFC methodology are introduced. Drawing lessons from various existing DFX methodologies, including design for assembly and design for variety, these concepts set out the basics for a novel DFC methodology. The debated DFC methodology is presented in the second part alongside an illustrative case study [1]. © IMechE 2006.