Ron Heiskell first tested the process that evolved into the ReducedEffort System at The Clorox Company, where he was an engineer for 24 years. When Ron was asked to teach SMED at The Clorox Company manufacturing plants, he agreed—in part because he saw it as his chance to try some new techniques. He knew that line workers had their own ways of performing changeovers and that many of them had been doing it the same way for a long time, often for 25 or more years with their paradigms being well established. Teaching SMED at The Clorox Company gave Ron the opportunity to try this new reduced-effort process in the real world. The results were so amazing that his job shifted from designing packaging lines to reducing changeover downtime in all the plants owned by The Clorox Company as well as those of its suppliers. After leaving The Clorox Company, Ron founded ReducedEffort, LLC, conducted Kaizen events at Fortune 500 companies, and published the book Reduced Effort Changeover: The Lean Way to Quickly Reduce Changeover Downtime.
Reduced Effort Changeover
Ron developed his method for shaving time off of changeovers (aka makereadies) while working in packaging for The Clorox Company. His twist was to not focus on time reduction but instead on reducing the effort of operators. And it worked—the results were so amazing that his job shifted from designing packaging lines to reducing changeover downtime in all company plants, as well as those of suppliers. He then documented the process in his book, Reduced Effort Changeover: The Lean Way to Quickly Reduce Changeover Downtime. In this session, Ron will explain each step of his process. Said one flexible package printing converter that has used it: “With his changeover process I am always super confident when leading operators in a Kaizen event because there are always amazing results.”