SMED, Single Minute Exchange of Dies, quick changeoversSMED, Single Minute Exchange of Dies, quick changeovers - different terms for very similar things.
SMED training towards Lean Six Sigma Certification Reducing Setup Times
SETUP: Work Required To Convert Process from Running One Part or Operation to Running Another. EXTERNAL SETUP: Work done while the machine is running good parts INTERNAL SETUP: Work done while the machine is not running good parts
SETUP TIME: Elapsed time from the last good unit of one production run to the first good unit of the next production run.
Standard Setup Activities Exchanging dies or tools 10% Positioning dies or tools 20% Making adjustments 45% Gathering necessary items 25%
Where is most of the time spent?
Five Steps to Quick Changeover
1. Observe the current process. 2. Differentiate internal & external. 3. Convert internal into external. 4. Streamline internal operations. 5. Streamline external operations.
Step 1. Observe the Current Process PROCESS ELEMENTS Start machine, wait on machine cycle. Remove and gauge part, place in bin. Obtain new parts, place in fixture, start machine.
Step 2. Differentiate Internal and External Stage all items before shutting down the machine Develop checklist for needed changeover items Store high-use items at the machine Use die charts and tool boards Use visual management: “on deck circle,” scheduling board Place tools and parts in order of usage Check all items to ensure proper fit and function Sharpen and Preset Tools Clean Fixtures and Verify Free of Defects Cleanup & Return Removed Tools After First Good Part
Step 3. Convert Internal to External Standardize Operations to Minimize Internal Adjustments Die pressures Size and shape Dies, tools, & jigs Bolts, hoses, & handles
Height and Stroke Die height Machine level Handling & storage level
Prepare operating conditions prior to the changeover Preheat, pre-set, pre-cut, or pre-adjust Form dress grinding wheels offline Use intermediary fixtures/jigs Presetting tools Positioning dies Replace fewest parts possible Position dies or tooling for quick insertion into machine
Step 4. Improve Internal Operations
Eliminate Time Lost Removing and Installing Bolts
Replace bolts with functional clamps
Eliminate all adjustments Graduated scales – Standardized settings Calibrated values – Setting gauges/blocks Measurement devices – Dead stop locations
Motion Element Analysis Move both hands at the same time Make two-handed motions brief and small Maximize use of hands and forearms for light work Avoid swift changes in direction Maintain appropriate center of gravity
Step 5. Improve External Operations
Avoid Time Lost Looking for or Verifying Correct Items: Color Coding Number Coding
Proper Arrangement and Orderliness Carts Reserved for Changeovers Material Flow Racks Go-No Go Gauges Simplify Adjustments Dedicated setup equipment and carts Continuously Collect Ideas to Improve Setup!
Remember that all improvements begin and end with the Five S’s! Sort Straighten Sweep Sustain Self-Discipline
SMED
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