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
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
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:
Proper Arrangement and Orderliness
Carts Reserved for Changeovers
Material Flow Racks
Go-No Go Gauges
Dedicated setup equipment and carts
Continuously Collect Ideas to Improve Setup!
Remember that all improvements begin and end with the Five S’s!