Reducing changeover times.

It takes the average motorist about an hour to change four wheels on a car; it takes a team of Formula 1 mechanics just seven seconds. Manufacturing industries have much to learn from the world of motor racing in improving changeovers between production processes - everyone in the changeover team knows exactly what to do, when to do it, how to do it and has the skills required to perform each task; the materials are in the right place at the right time; all the tools and equipment are well maintained and thoroughly prepared; the team constantly practises and aims to improve; and everyone is recognized as being a valuable team member.

In their quest for competitive advantage, most organizations have focused on the production process itself as a way of increasing responsiveness and reducing costs. However, minimizing the …