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 6 – Separation between internal and external moments. The purpose is to secure that all external set-ups are performed when the machine is running. Use checklists, function controls and improved transports. For example collect necessary tools and consumables before the next operation starts up or sharp the tools before activity starts.
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

SMED Quick Change-Over

PowerPoint, Manual, and Work-Shops
Free demo

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)

Pages with the most "likes":

1 5S PowerPoint - Five Steps to a Better Workplace

2 Kaizen - The zen of doing it better, and making it better

3 Z-value: Setting the Standard

4 Kanban Calculator- A Card to Pull Production

5 MTBF and MTBR

I am a Swedish-based Lean consultant, and the owner of the World-Class-Manufacturing.com web site.

Contact Oskar Olofsson

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