Resource:SMED (Single Minute Exchange of Dies), Goal, Objectives, Benefits, Complete Operation, Three Steps of SMED & Further Improvement in SMED
• Quick Changeovers – SMED (Single Minute Exchange of Dies)
[PRODUCT COMPLEXITY INTEGRATION]
Single Minute Exchange of Dies (SMED)
• Driven by the need to change over a process to produce a product in the most efficient manner. Reducing Setup (or Change Over) is the technique allowing the mixing of production/products without slowing output or creating higher costs associated with non‐value adding activity. Changeovers add no value and therefore should be minimized.
Goal of SMED
The goal is to reduce and/or eliminate downtime due to setups and changeovers
Objectives of SMED
• Minimal loss of throughput time on equipment.
• The ability to run a greater variety of product mix using a particular resource.
• Building only what is needed today.
Benefits of SMED
• Quick Changeover will:
– Increase productivity
– Reduce lead time
– Lower total costs
– Increase flexibility for adapting to a changing market
• Maximize external setup to total setup ratio
• Minimize internal setup to total setup ratio
Three Steps of SMED
• Segregate the setup activities
• Re‐categorize the activities
• Streamline all aspects of the setup operation
Step 1 : Segregate the setup activities
• Develop check list include every single item necessary for running next operation
• Identify & document all activities in the process
• Breakdown Identified activities in two category:
1. Internal Setup: Activities which have to perform when the machine is down.
2. External Setup: Activities which have to perform when machine is running
Step 2 : Re‐categorize the activities
• Identify internal setups that could potentially be moved to external
– Convert internal setups to external setups
– Preparing operating conditions in advance
– Standardize essential functions
Step 3 : Streamline all aspects of the setup operation
• Reduce or eliminate steps as they are done today.
• Make sure sequence of each operation is ideal.
• Consider the following to streamline both internal and external setups:
1. How every thing involved is organized and sequenced. If any of the processes can be organized more efficiently, consider altering them.
2. Determine how much buffer must be kept on hand to run smoothly.
Further Improvement in SMED
Once setup activities have been documented and re‐categorized, the last step is to look at simplifying the setup process for both internal and external activities. Investigate standardizing
the setup, minimizing the utilization of bolts and adjustments, and utilize simple one turn type attachment methods and techniques such as cams, interlocking mechanism, slotted bolts
secured washers etc.
• Elimination of changeover downtime and delays to avoid the resulting loss of productive capacity.
• Thus, by eliminating changeover delays, our objective is to:
– Increase productivity
– Improve on‐time delivery
– Reduce cost per part