I'm a Swedish-based Lean consultant, and the owner of the free World-Class-Manufacturing.com web site.
In short, I teach key descision makers how to get a cost-effective and robust production.
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Single Minute Exchange of Dies (SMED)
SMED in brief
- No set-up should take more than 9 minutes
- It is a systematic approach that decreases disturbances and problem
- Based on team-work and creativity
- SMED methods is used for exchange of dies, but also for cleaning, and for regular maintenance
Change over time is defined as the time difference of the last product produced and the next new product produced with the right quality and at the right speed.
Why decrease set-up times?
Production sites with long set-up times are characterized by
- Low flexibility
- Large batch sizes
- High level of stocks
If we decrease the set-up times we could use the extra capacity either to increase productivity or to decrease the batch sizes. Typical benefits are:
- Reduction in lead time and hence improved and faster delivery
- Higher productivity
- Reduction in working capital
- Makes Kanban – systems possibly
- Less disturbances
SMED Implementation
So how could SMED be effectively implemented?
Based on my experience, the following steps are the key treads that would best guarantee the successful implementation:
Step 1 Focus. Start by choosing the right equipment to start with. This is normally a bottle-neck with long set-up times
Step 2 Build the right team. Work cross-functional. Operators, Technicians, Engineers and Managers should work together
Step 3 – Measure and set goals. Visualize the present situation and agree on a common goal
Step 4 – 5S. To succeed you will need a clean and well organized work-place. A 5S implementation is recommended
Step 5 - Analysis. Keenly observe the operations and processes. Analyze the present situation video-technique. The different moments are classified as being external or internal and waste or not waste. All known disturbances are listed as well.
"SMED Video analysis "
Step 7 - Elimination of waste. Measures are carried out to reduce all types of waste. This includes:
- Elimination of all need for adjustments.
- Exchange of bolts for quick-fasteners.
- Standardized parts, tools, dimensions
- Increased number of equipments
- Improved team-work.
- Need for quality control
Step 8 Follow up and improve. Make sure that your new level sets the new standard
Oskar Olofsson, 2009
References:
1 Quick Changeover for Operators Learning Package: A Revolution in Manufacturing: The SMED System
2 Quick Changeover for Operators: The SMED System (Shopfloor Series)