SINGLE MINUTE EXCHANGE OF DIES (SMED)

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INTRODUCTION OF SINGLE MINUTE EXCHANGE OF DIES (SMED)

SMED stands for Single Minute Exchange of Die. Quick Changeover, often referred to as SMED or Setup Reduction, is a fundamental concept in Lean production eliminates or reduces non-value-added activities in the setup and teardown processes of manufacturing, allowing companies to quickly and efficiently change from one product to another.

Quick Changeover is a critical component of Lean Manufacturing, time spent in setting up equipment for production does not add value, is considered waste, and waste must be reduced or eliminated, SMED setup reduction methods aim to reduce production changeover to the shortest possible time. In addition to improving cycle time in a process, SMED can help reduce costs and increase flexibility within a process.

The training follows the principles first expressed by Dr. Shigeo Shingo and his work on Single Minute Exchange of Die (SMED).

 

COURSE OBJECTIVES

Participants learn the standard methodology in applying SMED. The techniques covered demonstrate how to reduce changeover time from hours to minutes and even seconds.

  • Reduce Inventory costs
  • Increase Production Flexibility
  • Improve on-time delivery
  • Understand how quick changeover/setup reduction supports lean manufacturing
  • Learn key concepts and principles related to Quick Changeover/setup reduction
  • Develop skills required to apply Quick Changeover using a disciplined, visual process of documentation and improvement
  • Experience a team approach to quick changeover/setup reduction
  • Recognize how quick changeover/setup reduction can be applied to support functions throughout the value chain

 

COURSE CONTENT

Module 1: Introduction

  • A Brief History of SMED
  • Types of Maintenance
  • What is SMED?
  • Benefits of SMED
  • The roles of SMED
  • Waste Management
  • Setup Practices
  • Traditional /Strategic Setup Approach

Module 2: Single Minute Exchange of Die: Overview

  • Definition of Changeover Time
  • Why decrease set-up times?
  • Changeover as a process
  • Traditional Changeover and the Wastes of Lean
  • Benefits of Shortening Changeover Time
  • Changeover time and overall process time
  • Identify changeover improvement priorities
  • SMED Benefits

Module 3: What are the Essential Disciplines of SMED?

  • Teamwork
  • Standardization, Benchmarking & Simplification
  • The Procedural Training System
  • Key Result Analysis System
  • Information Management System
  • Inventory Management System
  • Just-In-Time Organization
  • Time Management System
  • Parallel Processing
  • One Touch Tooling
  • Logout/Tag Out (LOTO)
  • The use of tools and importance of correct tools
  • Mistake Proofing
  • System Maintenance

Module 4: The 4 conceptual stages of SMED

  • Steps To Implement SMED
  • Preliminary stage
  • Identify internal vs. external changeover tasks
  • Analyze each task’s real purpose and function
  • Focus on no/low-cost solutions
  • Aim to eliminate changeover time

 

    • Stage 1: Separating internal and external setup
      • Develop and implement changeover checklists.
      • Perform function checks on parts and tools.
      • Reduce transportation of tools, parts, and materials.
      • SMED: Separate Internal and External Setup
      • Develop specific checklists for every piece of equipment and major process.
      • Are all of the changeover materials in good working order?
      • Have all materials been checked far enough in advance to allow time for repairs?
      • Reduce non-value-added movement of changeover parts, tools, and materials
      • Transport changeover materials before the machine shuts down
      • Focus on no/low-cost solutions
    • Stage 2: Converting internal setup to external setup
      • Focus on functions such as dimensioning, securing, gripping, and centering
      • Replace the fewest possible parts by changing the way we perform the function
      • Design and build standard-sized, removable plates or frames
      • Externally attach and adjust die/parts
      • Eliminate internal adjustments to individual parts during changeover
    • Stage 3: Streamlining all aspects of the setup process
      • Divide changeover tasks between two or more people.
      • Maintain detailed changeover procedures.
      • Use visual marks to indicate correct settings
      • Create “quick set” mechanisms to handle different functions
      • Install fixed stops to indicate where a part should be positioned

 

Module 5: Implementing Single Minute Exchange of Die

  • SMED Implementation Planning
  • The Use of Functional Clamps
  • Implementation Team
  • Implementation Plan
  • Elimination of Adjustments
  • How The Boltless Method Is Used
  • Communication Plan
  • Training Plan
  • Implement Quick Changeover improvements
  • Monitor and document results
  • Develop a plan to standardize improvements
  • Accelerate Progress

 

Module 6: Improve Occupational Health and Safety (OHS)

  • Identify hazards to self or others in all steps/actions
  • Determine risks from each hazard
  • Identify actions which may be performed in a more ergonomic manner
  • Recommend changes to improve OHS
  • Monitoring and continuous improvement for setup reductions

 

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