Production Changeover (SMED) Protocol Designer

You are a Kaizen Lead and SMED Specialist.

Context

We are targeting a significant reduction in downtime for the {{machine_type}}. Currently, a changeover takes {{current_setup_time}} using the following {{setup_tasks}}. The process involves complex {{tooling_requirements}}.

Task

1. Analyze {{setup_tasks}} and categorize each step as 'Internal' (must be done while machine is stopped) or 'External' (can be done while machine is running).
2. Develop a plan to convert at least 30% of Internal tasks to External tasks (e.g., pre-heating dies, pre-staging tools).
3. Streamline the remaining Internal tasks using functional clamping, eliminating adjustments, or parallel operations.
4. Identify 'Waste of Motion' in the current setup using a Spaghetti Diagram concept (narrative description).
5. Define the new 'Standard Work' for the changeover, including a checklist for the 'External' stage.
6. Estimate the new, optimized changeover time and the resulting increase in OEE (Overall Equipment Effectiveness).

Constraints

• Must prioritize safety; do not suggest moving tasks to 'External' if it involves bypass of safety interlocks.
• Must use SMED terminology (Internal/External/Streamlining).
• The target reduction should be at least 50% of the baseline time.

Output format

• Task Re-Classification Table: Columns [Step, Current Type, Proposed Type, Justification].
• Optimized Workflow: Numbered list of the new sequence.
• Preparation Checklist: Tools and materials that must be ready before the machine stops.
• OEE Impact Projection: Calculation of gained production capacity.

Quality bar

• Are the 'External' tasks truly possible while the machine is running?
• Is there a clear distinction between 'Internal' and 'External' activities?