SMED

A Set-Up Reduction Tool for Continuous Improvement

Definition Setup Reduction (Quick Changeover)

A Lean Manufacturing Tool It supports building products after a customer order is received, not on market forecasts.
Allows

an operation to fully utilize its assets by producing a wide variety of parts. Eliminates or reduces non-value added activities in all types of process setups to quickly change from one product to another. Reduces batch sizes and shortens lead time eliminating the expense of excess inventory.

Definition

- Single Minute Exchange of Dies

Subset of Setup Reduction focused on die exchange

Term is sometimes used to define all quick changeover initiatives SMED targets changeovers completed in less than 10 minutes (single minutes).
Uses

focused problem-solving or no cost approach.

Low-cost

Benefits of Quick Changeover

More frequent changes Smaller batches Lower inventory Better quality Less waste More Flexibility Less STRESS!!! Improved teamwork

Setup Reduction 4 Step Method

Changeover Time: The time between the last good piece of one production run and the first good piece of the production run after the changeover. Internal: Activities performed while the machine is shut down. External: Activities performed while the machine is safely running.
Set-up Time
1 Run A 2 Run A

Document current change over elements

External Internal External Run B

Separate Internal/External Activities

Internal Run B

50% Reduction

External
3 Run A 4 Run A

External

Shift Internal activities to external

Internal Run B 75% Reduction 90% Reduction

Streamline Internal/External Activities

Internal Run B

4 Step Method- Step 1

STEP 1
D, M

Document the setup and separate events into internal or external

Convert Internal to External events

STEP 2

Streamline internal events (Simplify, Reduce, Eliminate)

STEP 3

Eliminate adjustments internal to the setup

STEP 4

xx

Corresponding DMAIC phase for a stand-alone Setup Reduction project

Step 1 Application

Pre-Workshop Preparation Document Setup Activities by Performing Dry-Run of the Setup Document the Actual (Live) Setup

Video allows operators to review and explain their activities Record All Events and Times in the Setup Timeline

Separate Events into Internal Setup and External Setup

Brainstorm Around Setup Reduction Opportunities

Step 1Tools - Setup Reduction Worksheet

The Setup Reduction Worksheet is used to document the events performed during the setup.

Provides a time stamp for each event during the setup. The worksheet is used to identify internal and external events.

Step 1 Tools - Using the Area Layout

Hardware Cage Controls

Hand Tool Cabinet Punch Press #1465

Tool/Die and Fixture Room

Tool Carousel

Production Control

Quality Control

Step 1 Tools Before and After Setup Timelines

"Before and After Setup Timelines will visually compare and illustrate the improvements.

Improvement Worksheet is a list of brainstorming ideas for improvement.

Step 2 of 4
STEP 1 D, M Document the setup and separate events into internal or external

Convert Internal to External events

STEP 2

A, I

Streamline internal events (Simplify, Reduce, Eliminate)

STEP 3

Eliminate adjustments internal to the setup

STEP 4

I, C

Step 2 is drastically cut internal setup time

Corresponding DMAIC phase for a stand-alone Setup Reduction project

xx

Step 2 Application
Convert Internal to External Setup
Convert

any internal setup events to external setup events using focused, engineered methods. Re-examine internal events from Step 1 and verify that they are actually internal.

The most important step in implementing successful Quick Changeover is distinguishing between internal and external Changeover elements.

Step 2 Tools

Part # 432543 Press # P-10 Review Check Table Die 274 Functional Checks Die Location Shelf 4 Retrieve Change Parts
Time 8 9 10 11 12 13 Action Parts Setup A

ALLEN WRENCH CRESCENT SCREWDRIVER WRENCH

Setup

Organization Checklists Check Tables Battle Plans Functional Checks

Improving transportation

Step 2 Tools - Organize for Setup

Fact: Significant setup time is lost searching for setup hardware and setup information. Setup Hardware: Tools Fixtures Nuts and Bolts Clamping Devices Measuring Devices Setup Information: Data (Tool and Machine Settings) Procedures

Step 2 Example - Preassemble Parts

OLD 60 min
Die attached to machine

NEW - 15 min
Die preheated Die attached to machine

15 min

Die heated to temperature by injecting molten metal 60 min

First good casting made

First casting made

First casting removed and scrapped

First good casting made

Step 3 of 4
STEP 1 D, M Document the setup and separate events into internal or external

STEP 2 A, I Convert Internal to External events

Streamline internal events (Simplify, Reduce, Eliminate)

Step 3 fine-tune the internal events

STEP 3

Eliminate adjustments internal to the setup

STEP 4

I, C

xx

Corresponding DMAIC phase for a stand-alone Setup Reduction project

Step 3 Application
Streamline Internal Setup by:

Simplifying Movement
One-touch Single

tools

thread bolts the number of bolts

Reducing Movement
Reduce

Add

Parallel Operations Operating Conditions in Advance

Eliminating Movement
Prepare
Replace

bolts with hydraulic or camoperated clamps.

Step 3 Example - Nut/Bolt Improvement Methods

Reduce/eliminate need for hand tools Reduce/eliminate nuts and bolts, hex nuts, etc. Replace with quick fastening/releasing devices:
Single

motion securing

U-slot

method

Pear

shaped hole method

Step 3 Application - Nut/Bolt Improvement Methods

Reduce Number of Screws U-Slot Method Clamps Pear Shaped Hole Method Magnets

Snap Method

Single Motion Connections

One-Turn Method

Use of Cams

Toggle Clamps

Use Only 1 Type/ Size of Fastener

Step 4 of 4
STEP 1 D, M Document the setup and separate events into internal or external

STEP 2 A, I Convert Internal to External events

STEP 3 I Streamline internal events (Simplify, Reduce, Eliminate)

Eliminate adjustments internal to the setup

STEP 4

I, C

Use Step 4 to remove additional time

xx

Corresponding DMAIC phase for a stand-alone Setup Reduction project

Step 4 Application
Eliminating Adjustments and Trial Runs
Turn

intuition and guessing into data and settings.

Elimination

means elimination not reduction in the time required to perform adjustments.

Measurements and Settings 15% Setup 5%
Adjustments 50%

Preparation 30%

Step 4 Tools - Eliminating Adjustments

Abandon reliance on intuition for settings

Intuitive

settings are inexact and do not provide the required precision as data based settings intuition to DATA is the surest way to consistently avoid adjustments and test runs

Converting

Step 4 Application - Centering Method

Before
Adjustments

After

Fixture

Fixture

Machine Base Machine Center

Machine Base

Centering Ball Machine Center

Step 4 Application Results - Centering Method

Before
Place fixture onto base

After
Place fixture onto base centering using centering ball

1 min

Load and cut part Take measurements 8 min

Start production

Correct dimensions Start production

Make adjustments

Average 2 Scrapped Parts

Step 4 - Six Steps for Analyzing Effectiveness of Adjustments

(1) What is the steps function and is it necessary ? (2) Determine why the step is needed (3) What is the skill level of the Changeover operator? (4) Why is it necessary to perform it this way? (5) What conditions create the need for repeated adjustments? (6) Consider the alternatives that can eliminate or drastically reduce Steps 1-5 above, and then implement.

Establish Effective Measurement System

(1) OEE (Operational Equipment effectiveness) (2) Number of steps in changeover process. (3) Total time for an average changeover.

(4) Reduced lead time.

(5) Machine run time / utilization time.

(6) Number of products produced

(7) Lot Sizes.

Insures projects take on a results orientation that is measurable and positively impacts performance parameters.

Service and Office Opportunities

Service Waste

Office Process Waste

Errors in documents Transport of documents Doing unrequested work Waiting fore the next step in the process Process for getting approvals

Too many signature levels Unclear job descriptions Obsolete databases/files/folders Purchase orders not matching quotes / receiving / invoices Errors typos, misspellings, wrong data Waiting for information, at meetings Poor office layout Unnecessary emails

Unnecessary motions
Backlog in work queues Under-utilized employees

Other Quick Changeover Opportunities

Separate internal from external time

Printer Out of ink - Internal time from last printed sheet to next printed sheet Have the next task or project prepared and waiting for you in a folder instead of searching for it and the instructions

Cut-out Waste

An office machine requires multiple settings use a one-touch method Reduce the number of clicks to access information from a computer system

Parallel Systems (Pit crew mentality)

Cleaning an office w/multiple people doing specific tasks Have a team make sales phone calls by using aides to prepare the customer information ahead of the Sales Reps call Surgery preparation for the patient and the actual procedure Catering a dinner with appetizer, entre, salad, and desert teams

Tools

Add RAM to your computer to speed up processing Use multiple monitors instead of flipping through multiple screens Use vacuum cleaners instead of brooms

Standardized Work in a Doctors Office

What Have We Learned.

Setup Reduction (Quick Changeover) is a Lean Tool The term SMED is sometimes used in place of Setup Reduction, but refers to die change improvements Setup reduction is a requirement for batch size and overall lead time reduction. Apply this to the key time traps first. Use the four step method it works Measure It Use it on all types of process (even when you get coffee from a vending machine). A key element is 3C+C. (Communication, Cooperation, Consideration, &+ Commitment (to action)

Thank You Any Questions?