SMED (Single Minute Exchange of Die) this is a set of techniques that make it possible to improve changeover performance and increase OEE.

  • Objectives:
    • Reduced downtime
    • Increased flexibility
    • Improved set-up time
  • Goal:
    • 75% reduction in set-up with relatively little capital
  • Is not about:
    • People reduction

Set-up Time Definition

  • Set-up Time: the total amount of time to change over equipment or prepare during which the process is down
    • Unproductive downtime in manufacturing
    • Waiting time in a service setting

Total amount of time to change over equipment or prepare during which the process is down.

Internal vs External Time

  • Internal setup activities are those that can only occur while the process is off-line or stopped
  • External setup activities are those we can do before the process has to stop (prepared ahead of time)

SMED Methodology

Separate internal Set-up from external Set-up. Convert internal Set-up to external Set-up. Streamline all aspects of the Set-up operations.

Current Process

Changeover is the time from the last product of one run until the first product of the next run at the correct speed and quality.

Stage 1. Separate Internal from External

Internal set-up: machine must be stopped. External set-up: can be done while running.

Stage 2. Convert internal set-up to external set-up

Establish a plan to implement adequate techniques - as suggested the SMED.

Stage 3. Streamline Operations

Leave mechanism in the machine and just modify its function by setting

Stage 3

  • Reduce the need for “fine-tuning” or adjusting wherever possible

Wingnut and matching surfaces for SMED

  • Reduce complexity wherever possible

Usage of slots instead of series of holes for SMED

  • Keep all necessary tools and materials at the point of use

SMED tools in place

Keep all necessary tools and materials at the point of use

 

  • Automate cautiously
    • Automate only as a last resort and only if cost effective
    • Shigeo Shingo’s Rule of Thumb: automate only when set-up time is less than 3 minutes
  • Standardize
    • SOPs that reflects the improved set-up time
    • Standardize tools, fixtures, clamps, etc.
  • Understanding
    • Help people understand the why not just the how

Leave a Reply