Quick Changeover SMED

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Quick Change Over - on the base of Single Minutes Exchange of Dies ( SMED) helps you to reduce setup time, improve your effective machine running time, and surely increase the quality.
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Quick Changeover SMED

  1. 1. QUICK CHANGE OVER<br />Single <br />Minute <br />Exchange of<br />Dies<br />
  2. 2. 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 />
  3. 3. 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 />
  4. 4. 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 />
  5. 5. QUICK CHANGEOVER IN LEAN<br />
  6. 6. TRANSFORMATION<br />TRADITIONAL <br />VS <br />SMED<br />How long does it take to change the tire???<br />
  7. 7. 6 “Traditional” Setup Steps<br />
  8. 8. 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 />
  9. 9. The SMED Process<br /><ul><li>Reduce inventory
  10. 10. Reduce batch sizes
  11. 11. Reduce changeover time
  12. 12. Reduce impact on equipment utilization
  13. 13. Improve quality after changeover
  14. 14. Improve repeatability
  15. 15. Improve throughput
  16. 16. 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 />
  17. 17. 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
  18. 18. Explain why we are conducting an observation
  19. 19. We’re observing the activity not the person
  20. 20. What we are trying to accomplish
  21. 21. Explain the possible benefits for them and the company
  22. 22. Review the observation with the individual
  23. 23. Coaching
  24. 24. Clarification
  25. 25. Identify internal and external elements,
  26. 26. waste/lost time,
  27. 27. 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 />
  28. 28. 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 />
  29. 29. THE SMED PROCESS<br />How to convert externals to internals ?<br /><ul><li>Eliminate search-and-find work
  30. 30. Arrange tools & materials beforehand
  31. 31. Complete prep work before starting changeover
  32. 32. Standardize settings
  33. 33. Make visual marks vs. trial and error adjustments
  34. 34. Eliminate trial runs
  35. 35. 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 />
  36. 36. 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
  37. 37. Color coding
  38. 38. Standard set ups
  39. 39. Checklists</li></ul>ADOPT <br />QUICK DIE CHANGEOVER <br />( QDC) HARDWARE <br />
  40. 40. THE SMED PROCESS<br />5. DOCUMENT INTERNAL & EXTERNAL PROCEDURES<br /><ul><li>Make adjustments, as needed
  41. 41. Re-test, if necessary</li></li></ul><li>THE SMED PROCESS<br />5. DOCUMENT INTERNAL & EXTERNAL PROCEDURES<br /><ul><li>Make adjustments, as needed
  42. 42. Re-test, if necessary</li></li></ul><li>THE SMED PROCESS<br />5. DOCUMENT INTERNAL & EXTERNAL PROCEDURES<br /><ul><li>Make adjustments, as needed
  43. 43. 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 />
  44. 44. 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 />
  45. 45. IDEAS FOR IMPROVEMENT<br />Rollers<br />SET-UP <br />DIE CARTS<br />T<br />ools<br />T<br />urntable<br />Documentation<br />
  46. 46. 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 />
  47. 47. IDEAS FOR IMPROVEMENT<br />Clamping height<br />Add<br />spacers<br />here<br />Cut away<br />here<br />STANDARDIZE CLAMPING HEIGHT<br />
  48. 48. 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 />
  49. 49. 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 />
  50. 50. 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 />
  51. 51. 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 />
  52. 52.
  53. 53. Are you ready to face the <br />“World Class” challenge?<br />

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