MWS-01

ln Beginner/Intermediate

Chicago Manufacturing Center

George Alukal & Anthony Manos

Quick Changeover (QCO) using Single Minute Exchange of Dies (SMED) techniques

Set up time reduction (QCO) projects are performed as Kaizen Blitzes. The “Eight week” Kaizen with prior robust planning, a four (or five) day Kaizen event itself, plus the 30-day follow-up works best for standardizing at the improved level and for sustaining the “gains”. This four-hour workshop will describe how to implement an Eight week Kaizen.

The importance of teamwork, cultural change, preparation & communication, brainstorming ideas, “stretch” goal-setting, “internal” vs. “external” task analysis, aligning personal goals and converting the new way of setting up into “daily work”, senior management support, etc. for the success of any QCO/SMED project will be explained.

George Alukal

With more than 20 years’ experience in manufacturing, Mr. Alukal has expertise in general management, quality, process improvement and lean. He is a certified quality manager, auditor, engineer, and has passed the ISO 9000 lead assessor examination.

George Alukal was a member of the board of examiners for the Malcolm Baldrige National Quality Award and was a judge for the Illinois Manufacturing Association’s Team Excellence Award. He is an elected fellow and past chairman of the American Society for Quality (ASQ) Chicago Section and also served as director of their Training Institute. He is the founding chairman of ASQ’s Lean Enterprise Division and has developed and teaches ASQ’s two-day Lean course and one-day Kaizen course nationally. Besides that, George teaches several quality and process improvement courses, including ISO 9000, Lean Manufacturing, Six Sigma, Kaizen, Certified Quality Manager Refresher, etc. and is a speaker on TQM and Lean topics.

George has published many articles on Lean, and is the co-author of “Lean Kaizen” published by Quality Press in 2006.

George earned a B.S. in engineering from the Indian Institute of Technology, Madras, an M.S. in engineering from Cornell University and an M.B.A. in general management from the Kellogg School of Management of Northwestern University.

Anthony Manos

With more than 15 years experience in quality management, Mr. Manos is an expert in all aspects of quality, including developing and implementing programs, using statistical process control (SPC) and design of experiment (DOE), training, and auditing. He has guided many companies through implementation and certification for quality management standards such as ISO 9000 and QS-9000. Anthony Manos has extensive knowledge of lean manufacturing and quality in a wide range of work environments.

A sample of the types of training and implementation Anthony has provided include team building, standardized work, 5S Workplace Organization, Value Stream Mapping, Visual Factory, quick changeover, plant layout, Cellular Manufacturing, Pull/Kanban, TPM, and Kaizen Blitzes.

Anthony Manos is trained and certified by the National Institute for Standards and Technology (NIST/MEP) in all elements of Lean manufacturing. He is also a senior member of the American Society of Quality where he holds various certifications, including ASQ Certified Quality Manager, ASQ Certified Quality Engineer, ASQ Certified Quality Auditor, ASQ Certified Quality Technician, and ASQ Certified Mechanical Inspector.  He was past chair of the Illiana Section of ASQ and past chair of the Northern Illinois Quality Conference. Anthony is a Lincoln Award examiner (based on the Malcolm Baldrige National Quality Award). Anthony is a senior member of the Society of Manufacturing Engineers. He’s a past chair of ASQ’s Lean Enterprise Division and co-authored the book, “Lean Kaizen”. He is a graduate of Governors State University in Illinois and earned his MBA from University of Illinois, Chicago.