SMED

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SMED

• Single Minute Exchange of Die
• OR
• Quick Changeover

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Agenda
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AGENDA
Agenda

• Introduction
• Background and History
• What are we trying to accomplish w/SMED and why?
• How
• A look at Traditional Setup
• The steps to SMED
• Ideas for Improvement
• Examples
• Summary

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Introduction
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Core Concept of CI (continuous improvement)
Introduction Concept of CI
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INTRODUCTION
Introduction

• A quick way of changing the setup from one
  thing to another.

• Also known as Quick Changeover, reducing the time
  it takes to setup for the next kind of thing

• Examples of setups

• Welding Steel, then welding Aluminum

• Changing from Accounts Payable to Receivable

• Changing from one size drill bit to another

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HELPS
Introduction Helps..

• Reduce the need for large batches/inventory

• Reduce Handling waste (transportation)

• Smaller batch sizes help align output with the
  needs and requests of the customer

• Less inventory means defects will be easier to
  find and resolve

• Less inventory means raw materials will wait less

• Modifies the economic lot size calculation

• Increases uptime of . equip, people, systems

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Background / History
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Where did this come from?
Background History

• Developed in the 50s 60s by Shigeo Shingo,
  chief engineer of Toyota

• Land costs in Japan were very high, not feasible
  to store large inventories of vehicles

• Quick Changeover provided a solution to the
  common large batch sizes

• More importantly, there is nothing new here, all
  common sense things, once we change the way we
  look at inventory.

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What Are We Trying to Accomplish w/SMED Why
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What Exactly Are We Trying To Do?
Implementing SMED What?

• Reduce the time it takes to make the changeover
  from one product to another, from one thing to
  another.

• From 1 day to 1 hour

• From 1 hour to 10 minutes

• From 10 minutes to 30 seconds

• Reducing lost (wasted) time from CHANGEOVERS

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What is Changeover?
Implementing SMED Defining Changeover

• The process of converting a machine, line, or
  system from running one product to the next.
• The act of replenishing materials.

What is Changeover Time?

• The total elapsed time between the last unit of
  the previous run, to the first unit of the next
  run

(at full line efficiency, and quality)
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REALITY CHECK!
Implementing SMED Examples

• Is this even possible?

• Examples

• Changing a tire on the side of the freeway VS
  Nascar Pit Crew

• A shortcut on your desktop

• Tooling that can be used for more than one type
  of job.

• Screw drivers that load themselves

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More Examples
Implementing SMED Examples

• 50 ton press changed from one product to the next
  in under 2 minutes VS 3 hrs
• Video Clip Martin Doors

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The Benefits of SMED / Quick Changeover
Implementing SMED Why / Benefites

• Better quality, less variation
• Well defined cleaner setup processes

• Better Flexibility
• Rapid change from product to product
• Better able to respond to customer demand
• Example Woodland Furniture

• Lower Cost
• Less need to stock inventory between operations
  that require large amounts of set time

• Better worker utilization
• Less time spent on setup or waiting for the run
  to start

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The Benefits of SMED / Quick Changeover
Implementing SMED Why / Benefites

• It is a customer-driven requirement. Customers
  are demanding
• Product and service diversity
• Lower costs
• Higher reliability and quality

• So organizations must
• Produce smaller lots, more frequently.
• Expand the scope and diversity of products
• Reduce quality defects.

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The HOW of SMED
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The Traditional Approach to Setups
The How Traditionally

• Set ups are expected, something we have to live
  with, value not questioned
• Therefore
• Use highly skilled setup personnel
• Minimize product variety
• Combine lots
• Make large batches

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It looks like this
The How Traditionally

• Prepare
• Ensures that all the tools are working properly
  and are in the right location

• Shut Down
• Stop the equipment and/or process

• Removal /Exit
• Remove previous tooling, exit existing setup

• Installation / Entry
• Install or enter next setup

• Tweek
• Make adjustments to setup, setting process
  controls

• 1st Run and validation
• Sometimes called 1st Article, inspect to make
  sure setup meets standard

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The Steps of SMED
The How Steps

• Step 1 Observe, Record, Analyze

• Step 2 Recognize Internal and External process
  steps

• Step 3 Move internal to external

• Step 4 Streamline all activities.

• Step 5 Document improved process as
  Standardized Work (train, audit)

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Step 1 Observe, Record, Analyze
The How Step 1

• Same principles as taught in Standard Work for
  Operators
• Collect data on Time Observation Form
• Get good detail

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Step 2 Recognize Internal and External process
steps
The How Step 2

• Internal set-up activities.
• Elements in the changeover which can only be done
  when the machine is stopped.
• External set-up activities.
• Elements that can be performed when the machine
  is running.

• Examples of both???

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Step 3 Move Internal to External
The How Step 3

• Study each internal step and ask if it can be
  made external.
• What to look for
• Needed equipment hard to get to, not available
• Tools not readily available.
• Quality inspections of materials
• Ask why the remaining internal steps cant be
  external.
• Re-examine the true function of each step.
• What to look for
• Can process steps be run in parrallel?
• Can better documentation provide needed
  information

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Step 4 Streamline remaining activities
The How Step 4

• Analyze the activity, and discuss all possible
  ways of improving the step.
• Study the external activities as well as the
  internal activities.
• What to look for
• Fastenings Are bolts needed? If so remember
  that only the last turn tightens a nut or bolt.
• Standardize bolt heads.
• Standardize die heights.
• Equipment and material availability and
  accessibility.

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Step 5 Document improved process as
Standardized Work (train, audit)
The How Step 5

• Create necessary documentation
• See Standard Work training session
• Visual docs
• Can be used for training and Auditing

• Train Audit

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Examples
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Office SMED examples
Examples Office

• Computers that multi-task

• Three hole punch

• Frequently used applications open, shown at the
  bottom of the screen

• Frequently used applications open, shown at the
  bottom of the screen

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Manufacturing SMED examples
Examples Manufacturing

• Modified bolts, tighten in few turns

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Manufacturing SMED examples
Examples Manufacturing

• Make it easy to clean

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Manufacturing SMED examples
Examples Manufacturing

• Tools that line themselves up

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Manufacturing SMED examples
Examples Manufacturing

• Designs that dont require set ups

• Equipment that can do a variety of things

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Other SMED examples
Examples Other

• Using a team to parallel process the setup

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SUMMARY
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To Summarize
Summary

• SMED is all about reducing the amount of value
  added work time lost due to setups and
  changeovers
• Standardized Work goes hand in hand with SMED
• SMED Applies to more than just manufacturing, and
  more than just exchanging dies
• The only thing better than a quick changeover is
  no changeover at all

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Things to Remember
Summary Things to Remember

• Doing more than one thing at a time, parrallel
  processing
• Hitting a changeover or setup with a team
• Doing as much preparation ahead of time as
  possible.
• Multiple copies of setups

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