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QUICK CHANGE OVER<br />Single <br />Minute <br />Exchange of<br />Dies<br />

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Changeover time<br />Traditional setup<br />Single Minutes Exchange of Dies<br />QUICK CHANGE OVER<br />SMED Process Steps<br />Ideas for Improvement<br />CONTENTS<br />

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INTRODUCTION<br />Setup<br />Time<br />Mold Change<br />Colour Change<br />EQUIPMENT<br />SIX BIG LOSSES<br />Mold change<br />Inspect/Adjust<br />0<br />Breakdowns<br />Last good part<br />1st Piece Time<br />(good or bad)<br />1st Good <br />Piece Time<br />Available time<br />Setup/<br />adjustment<br />Changeover time: <br />Definition<br />Available operating time<br />Idling/minor stoppages<br />The time elapsed between when the last good pieceof product A comes off <br />and the first good piece of product B starts.<br />Speed<br />Actual operating time<br />Defects in process rework<br />Effective <br />Operating time<br />Start-up losses<br />

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INTRODUCTION<br />History : Land costs in Japan were very high, therefore it was not feasible to store large inventories of vehicles <br />QUICK <br />CHANGE OVERS<br />“A rapid and efficient way of converting a process from running the current product to running the next product “<br />Developed by Shigeo Shingo<br />( in the late 1950’s and early 1960’s) chief engineer of Toyota <br />Reduces the waste of inventory by creating shorter production runsthat better align with customer demand <br />

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QUICK CHANGEOVER IN LEAN<br />

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TRANSFORMATION<br />TRADITIONAL <br />VS <br />SMED<br />How long does it take to change the tire???<br />

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6 “Traditional” Setup Steps<br />

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INTRODUCTION<br />What is “World-Class” <br />in Quick Changeovers?<br />SMED: <br />Single Minute Exchange of Die<br />Concept that says all setups should and can take less than 10 minutes<br />OTED: <br />One Touch Exchange of Die<br />Concept that says all setups should and can take less than 100 seconds!<br />

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The SMED Process<br /><ul><li>Reduce inventory

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Reduce batch sizes

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Reduce changeover time

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Reduce impact on equipment utilization

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Improve quality after changeover

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Improve repeatability

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Improve throughput

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Improve flexibility</li></ul>GOALS<br />Document internal and external procedures<br />Convert internal activities to external activities<br />Separate internal and external activities. <br />Observe and record<br />Streamline all activities<br />

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THE SMED PROCESS<br />1. OBSERVE AND RECORD<br />REMEMBER!!!<br />These activities are not conducted for the purpose of eliminating jobs or reducing people!<br />We should always: <br /><ul><li>Notify the party to be observed ahead of time

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Explain why we are conducting an observation

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We’re observing the activity not the person

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What we are trying to accomplish

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Explain the possible benefits for them and the company

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Review the observation with the individual

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Coaching

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Clarification

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Identify internal and external elements,

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waste/lost time,

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variances from the standard process</li></li></ul><li>THE SMED PROCESS<br />Run<br />All Setup <br />Activities<br />I<br />I<br />I<br />I<br />E<br />E<br />E<br />E<br />Run<br />Internals<br />Externals<br />Run<br />2. SEPARATE INTERNAL AND EXTERNAL ACTIVITIES<br />Internal elements: <br />operations that must be performed while the machine/process is stopped<br />Post-setup<br />External elements: <br />operations that can be performed while the machine/process is running<br />Externals<br />externals<br />

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THE SMED PROCESS<br />Internals<br />Externals<br />Run<br />Internals<br />Run<br />Externals<br />Internals<br />3. CONVERT INTERNALS TO EXTERNALS ACTIVITIES<br />Internals<br />Externals<br />Run<br />Internals<br />Externals<br />Run<br />Eliminate adjustment<br />Run<br />Externals<br />

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THE SMED PROCESS<br />How to convert externals to internals ?<br /><ul><li>Eliminate search-and-find work

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Arrange tools & materials beforehand

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Complete prep work before starting changeover

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Standardize settings

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Make visual marks vs. trial and error adjustments

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Eliminate trial runs

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Postpone “put away” work</li></li></ul><li>THE SMED PROCESS<br />4. STREAMLINE ALL ACTIVITIES<br />BEFORE<br />Last good piece of product A<br />First good piece of product B<br />Streamlined <br />External<br /> elements<br />Streamlined <br />External<br />elements<br />Last good piece of product A<br />First good piece of product B<br />AFTER CHANGE OVER<br />Streamlined<br />internal <br />elements<br />Machine<br /> running<br />Machine<br /> running<br />Last good piece of product A<br />First good piece of product B<br />External elements<br />External elements<br /> Total <br /> setup<br />Machine<br /> running<br />Machine<br /> running<br />Internal<br /> elements<br />Machine<br /> running<br />Machine<br /> running<br />Internal and external elements<br />STREAM<br />LINE<br />Total setup<br /> Total setup<br />

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THE SMED PROCESS<br />STREAMLINE <br />INTERNAL PROCESS<br />STREAMLINE<br />EXTERNAL PROCESS<br />Create Parallel steps – completed at the same time<br />Reduce complexity and eliminate waste<br /><ul><li>Use functional fixtures and jigs</li></ul>one motion fasteners<br />levered or one-turn fasteners<br />interlocking wedge or slot<br /><ul><li>Eliminate adjustments</li></ul>use angle and flat<br />use preset pins, guides, notches etc.<br /><ul><li>Eliminate need to leave the machine</li></ul>Use POUS and water spider<br />Adopt functional standards<br /><ul><li>Visual factory locations for tools

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Color coding

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Standard set ups

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Checklists</li></ul>ADOPT <br />QUICK DIE CHANGEOVER <br />( QDC) HARDWARE <br />

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THE SMED PROCESS<br />5. DOCUMENT INTERNAL & EXTERNAL PROCEDURES<br /><ul><li>Make adjustments, as needed

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Re-test, if necessary</li></li></ul><li>THE SMED PROCESS<br />5. DOCUMENT INTERNAL & EXTERNAL PROCEDURES<br /><ul><li>Make adjustments, as needed

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Re-test, if necessary</li></li></ul><li>THE SMED PROCESS<br />5. DOCUMENT INTERNAL & EXTERNAL PROCEDURES<br /><ul><li>Make adjustments, as needed

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Re-test, if necessary</li></li></ul><li>WHEN SHOULD YOU AUTOMATE??<br /><ul><li>Criterion 1: </li></ul>The operation has already been dramatically simplified<br /><ul><li>Criterion 2: </li></ul>Begin with semi automation to achieve 80% benefit at 20% cost<br /><ul><li>Criterion 3: </li></ul>The automation is cost-effective<br />

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IDEAS FOR IMPROVEMENT<br />Gauges<br />Set blocks<br />Stop gauges<br />Setup sheet<br />Prints<br />Special instructions<br />Special tools<br />SET-UP TOOL CARTS<br />

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IDEAS FOR IMPROVEMENT<br />Rollers<br />SET-UP <br />DIE CARTS<br />T<br />ools<br />T<br />urntable<br />Documentation<br />

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IDEAS FOR IMPROVEMENT<br />Slide<br />Slot<br />Model<br />value<br />address<br />ORGANIZE & STORE IN PROXIMITY<br />Block<br />gauge #<br />Cover<br />Line #<br />Part<br />Slot address labels<br />

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IDEAS FOR IMPROVEMENT<br />Clamping height<br />Add<br />spacers<br />here<br />Cut away<br />here<br />STANDARDIZE CLAMPING HEIGHT<br />

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IDEAS FOR IMPROVEMENT<br />Dial gauge<br />Linear gauge<br />& pointer<br />Adjusting<br />screw<br />Adjusting<br />wedge<br />Adjusting<br />pin<br />Better Still<br />Better<br />Interior space<br />Spring<br />(inaccessible)<br />plate<br />

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L<br /> clamp<br />Socket wrench <br />removes screw<br />Socket head cap screw<br />Nut is not removed <br />for setup!<br /> 4-piece clamp<br />4<br />3<br />2<br />IDEAS FOR IMPROVEMENT<br />AFTER<br />Die heights vary<br />Standardize clamp heights on dies<br />Streamlined 1-Piece Clamp<br />Spring<br />Spring<br />BEFORE<br />1<br />Die<br />Die<br />Bolster<br />Plate<br />Bolster<br />Plate<br />

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Before<br />IDEAS FOR IMPROVEMENT<br />Mold<br />Cam<br />lock<br />Stopper<br />After<br />TOGGLE LOCK DOWN CLAMP<br />QUICK RELEASE CAM LOCK<br />Eliminate bolts<br />

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IDEAS FOR IMPROVEMENT<br />Die<br />Before<br />Top view<br />Bolster<br />Die<br />Slot<br />2. Tighten<br />After<br />Side view<br />Bolster<br />1. Lift<br />Bolt & Slot<br />Centering Jig<br />Hinged Bolt<br />

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Are you ready to face the <br />“World Class” challenge?<br />