The video above is from Lean Strategies International LLC's Quick Changeover with REDUCE Course.
Of all the steps in a setup or changeover reduction, separating internal and external activities may in fact be the most important as well as the simplest steps you can take. In the most general sense, performing activities like preparing tools, kits and materials as well as transporting items while your line is running can reduce setup time by as much as 50%.
Differentiate Internal and External Activities
As a reminder, internal tasks are those tasks that can only be performed while the machine is stopped. External tasks on the other hand can be performed while a machine is running. When we look to differentiate between the two, we are trying to separate work elements or tasks into a group of internal and external tasks.
There are many tasks that can be performed before a machine is stopped. Let’s look at our indy car for a few common examples. Some of the more obvious ones that occur here are: