Practice New Setup and Document

New Standards
Practice the new Setup
There is an often missed, but extremely important aspect of the changeover reduction
process namely that we must practice the new method. In other words, once all of the
brainstorming and improvements have been implemented its time to pilot the new process.
But before we do the pilot its crucial that we have an excellent understanding of who will do
what, where all of the tools and supplies will be located, and of course everyone needs to
know, and be trained, on how to do the job safely and effectively.
Once everyone knows what to do and how to do it its time to practice the new
changeover process repeatedly. And while practicing wed like to encourage you to video
tape these practice sessions as there is often much to learn.
There are several tools
and templates that can,
and should be used
during this practicing
phase (and beyond).
The first is a simple graph
as shown here that
shows the changeover
times against the
changeover target. By making changeover times visual an organization will be sure to
continuously improve while also identifying weaknesses and opportunities for improvement.
The next tool that should be used is the changeover checklist that basically outlines what is
needed for the changeover to begin. An example template is available for download in the
resources section.

6. Practice New Setup and Document New Standards

Document the New Standard

Now then, once you and your team are satisfied with the new and improved process after
practicing and piloting its time to document the new standard. And while there are many
ways to go about this one of the best techniques is to create standardized work instructions
as shown to the right.
Once this standard work document is in place
all associates should know what they are
supposed to do and approximately how long it
should take. And, most importantly, they will
be able to refer to this sheet is an issue ever
arises allowing the team to ask why before
implementing countermeasures.
Please note that a standard work template is available for download in the resources section
of the Gemba Academy website.
In addition to standard work instructions, its also important to ensure all associates are cross
trained and able to do any job required. To help facilitate this a skill matrix can be utilized.
Please refer to the 5S Workplace Productivity course for more details on the skill matrix.
Finally, its very important to continuously monitor changeover times on visual boards for all
to see as this will definitely help facilitate continuous improvement while also enabling the
team to identify the times they dont meet their goal which of course will allow them to ask
why which will then lead them to hopefully implement countermeasures.

6. Practice New Setup and Document New Standards