SMED, Single Minute Exchange of Dies, quick changeovers

SMED, 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

Lean Six Sigma Training and Certification. Yellow, Green and Black Belt Certification, Increase your income by investing in yourself.


[?]Subscribe To This Site Home 5S Kaizen LSS Online Lean Definitions Lean Certification LSS Blog	SMED, Single Minute Exchange of Dies, quick changeovers SMED, 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 Lean Six Sigma Training and Certification. Yellow, Green and Black Belt Certification, Increase your income by investing in yourself.