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1Marek.Piatkowski@Rogers.com
SMED – Set-up
Reduction
Introduction
Thinkingwin, Win, WIN
SMED – Changeover Times
Introduction
Marek Piatkowski – January 2017
Thinkingwin, Win, WIN
2Marek.Piatkowski@Rogers.com
SMED – Set-up
Reduction
Introduction
Thinkingwin, Win, WIN
Introduction - Marek Piatkowski
 Professional Background
 Toyota Motor Manufacturing Canada (TMMC) - Cambridge, Ontario from
1987-1994
 TPS/Lean Transformation Consulting - since 1994
 Professional Affiliations
 TWI Network – John Shook, Founder
 Lean Enterprise Institute (LEI) – Jim Womack
 Lean Enterprise Academy (LEA) – Daniel Jones
 CCM/CAINTRA – Monterrey, Mexico
 SME, AME, ASQ, CME
 Lean Manufacturing Solutions - Toronto, Canada
http://twi-network.com
3Marek.Piatkowski@Rogers.com
SMED – Set-up
Reduction
Introduction
Thinkingwin, Win, WIN
4Marek.Piatkowski@Rogers.com
SMED – Set-up
Reduction
Introduction
Thinkingwin, Win, WIN
What is SMED?
 Single-Minute Exchange of Die (SMED) is one of the many lean production methods
for reducing waste in a manufacturing process.
 The name Single-Minute Exchange of Dies comes from the goal of reducing
changeover times to the “single” digits (i.e. less than 10 minutes).
 SMED was developed by Shigeo Shingo, a Japanese industrial engineer who was
extraordinarily successful in helping companies dramatically reduce their
changeover times in a Stamping Press shop.
 His pioneering work led to documented reductions in changeover times averaging
94% (e.g. from 90 minutes to less than 5 minutes) across a wide range of
companies.
 The SMED process focuses on making as many elements as possible external, and
simplifying and streamlining all elements.
5Marek.Piatkowski@Rogers.com
SMED – Set-up
Reduction
Introduction
Thinkingwin, Win, WIN
What is Set-up (Changeover) Reduction?
 SMED was developed at Toyota in a Press shop to exchange stamping dies.
 Many operations, for example paint, assembly, welding, testing do not use dies, but
they do face production model (product type) changes.
 Set-up (Changeovers) reduction process is a systematic approach to reduce stop-
time of any machine or a process during a model or product change
 Set-up reduction is a methodology for improving a process of converting a
manufacturing process from running the current product (model) to running the
next product (model)
 Set-up definition:
 The amount of time taken to change over a piece of equipment from the last piece
of a production lot to the first good piece of the next production lot.
6Marek.Piatkowski@Rogers.com
SMED – Set-up
Reduction
Introduction
Thinkingwin, Win, WIN
Why do we need to reduce Set-up times?
 Reduce equipment downtime
 Speed and flexibility:
 To shorten lead times - increases scheduling flexibility/capacity
 To produce less Inventory – frequent small batch production
 Shorter runs
 Quicker response – increases production flexibility
 Quicker setups
 To benefit Operators
 Standardized process - Safer changeovers
 Less clutter
 Few tools to keep track of
 Less adjustments means less chance for errors
7Marek.Piatkowski@Rogers.com
SMED – Set-up
Reduction
Introduction
Thinkingwin, Win, WIN
Typical Set-up Activities
30% - Preparing and
storing materials, dies,
fixtures, parts and tools
5% - Clamping and removing
parts, dies and tools
30%
5%
15% - centering and determining
dimensions of tooling
15%
50% - Trial processing, machine
programming or settings, after-
process adjustment and checking
50%
8Marek.Piatkowski@Rogers.com
SMED – Set-up
Reduction
Introduction
Thinkingwin, Win, WIN
Set-up Reduction Process
1. Video tape the set-up
2. Separate internal and external activities
3. Shift internal activities to external activities
4. Improve all work methods of the operation
5. Standardize what has been done
9Marek.Piatkowski@Rogers.com
SMED – Set-up
Reduction
Introduction
Thinkingwin, Win, WIN
Step 1 - Video tape the set-up
 Capture all activities that occur
 Focus on the machine, do not follow operators
 Do not turn off the video recorder for any reason during the set-up
 Get as much detail as possible
 Identify all parts produced on the equipment
 Select 2-3 part numbers for setup observation
 Identify external items needed for each part’s setup
 Create an external items checklist
 Gather fixtures, tools, and part drawings
 Make notes at any time (Voice-over, Notebook, etc.)
 Identify work elements
 Map process flow
 Make time observations
10Marek.Piatkowski@Rogers.com
SMED – Set-up
Reduction
Introduction
Thinkingwin, Win, WIN
Spaghetti Diagram
11Marek.Piatkowski@Rogers.com
SMED – Set-up
Reduction
Introduction
Thinkingwin, Win, WIN
Document a current process
1
2
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5
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20
21
22
23
24
25
VACIA MANGUERA DE PRODUCTO QUE QUEDA EN LA
LINEA DE ALIMENTACION
AFLOJA ELEVADOR PARA AJUSTE DE BOQUILLA
ESPERA CORTE DE CICLO DE DRENADO
LIMPIA MESA TIRA BOTELLAS SOBRANTES DE
CORRIDA ANTERIOR
TOMA MANGUERA EN SALIDA DE DRENAJE
ORGANIZANDO PARA EL CAMBIO CON OPERADOR B
CAMINA POR MANGUERA A EVA 12
REALIZA CAMBIO DE BOQUILLA POR BOQUILLA
METALICA
RETIRA CUBETA DE PURGA DE MAQUINA
REAPRIETA TORNILLOS DE ELEVADOR
CONECTA LA MANGUERA A TUBERIA DE AGUA
ESPERA A LLENARSE LA TOLVA DE AGUA
TOMA TRAPEADOR Y LIMPIA AREA
AJUSTA TIEMPO DEL CICLO DE DESAGUE
INICIA TERCER CICLO DE DESAGUE
ESPERA CORTE DE CICLO DE DESAGUE
AJUSTE DE TIEMPO DE LAVADO
RETIRA ENVASES DE CORRIDA ANTERIOR A KANBAN
REAJUSTE DE CICLO DE DESAGUE
INICIA CICLO DE DRENADO DE AGUA
REAJUSTA ALTURA DE ELEVADOR
INICIA SEGUNDO CICLO DE DESAGUE
OPERADOR A
ACTIVIDADES
TOLVA TABLERO
MESA
MESADE
EMPAQUE
PT
KANBANMP
MANGUERASDE
ALIMENTACION
PASILLO
TARIMAS
AREADE
PATIN
LAVADO
DRENAJE
DRENAJE
2
7
8
5
6
1
4
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10
12
15
13
11
9
17
21
22
20
18 23
25
24
E
V
A
1
2
SOPLETEADO
46:13 min
DURACION:
METODO
ANTERIOR
LAY OUT EVA-01
METODO DE TRABAJO PARA CAMBIO DE
PRODUCTO
RESPONSABLE:
46:13 min
12Marek.Piatkowski@Rogers.com
SMED – Set-up
Reduction
Introduction
Thinkingwin, Win, WIN
Step 2 - Separate internal and external activities
 Analyze the video tape:
 Use the “Set-up time breakdown sheet” to list all activities that take place
 How many adjustments?
 How many bolts or clamps are loosened / tightened?
 How many different tools are used?
 What’s the travel distance to get tools / materials?
 How many pieces of paperwork are used?
 How many checks are conducted?
 How many shots (injection molding), cuts (machining), or passes (grinding) are done
on a good part?
 Determine if the activities are “External” or “Internal”
 External activities are ones that are done while the machine is running production
 Internal activities are ones that are done while the machine is idle (stopped)
13Marek.Piatkowski@Rogers.com
SMED – Set-up
Reduction
Introduction
Thinkingwin, Win, WIN
Step 3 - Shift internal activities to external activities
 Determine which activities could be done while the machine is in production
 Brainstorm potential solutions
 Pre-setup activities (before the machine stops):
 Tools cleaned, sharpened, etc …
 Gauges preset
 Materials transported / sequenced
 Tools / fixtures staged
 Post-Set-up activities (after new production started:
 Setup for the current batch is complete
 Clean, inspect, repair (if needed) tools and fixtures
 Store all items in assigned locations
14Marek.Piatkowski@Rogers.com
SMED – Set-up
Reduction
Introduction
Thinkingwin, Win, WIN
Step 4 - Improve all work methods of the operation
 Brainstorm possible solutions to the set-up process
 Eliminate adjustments
 Standardize Clamping Height
 Position all materials near point-of-use
 Do we need a set-up cart?
 Develop an “Action Plan”
 Try different methods – Test Runs
 Eliminate bolts (e.g. use quick release mechanisms or other types of functional
clamps)
 Eliminate unnecessary motion (e.g. reorganize the work space)
 Eliminate waiting (e.g. make first article inspection a high priority for QA)
 Mechanization is normally considered as a last resort
15Marek.Piatkowski@Rogers.com
SMED – Set-up
Reduction
Introduction
Thinkingwin, Win, WIN
SMED Process Improvements – what to look for
 Shortages, mistakes, inadequate verification of equipment causing delays and can be
avoided by check tables, especially visual ones, and setup on an intermediary jig
 Inadequate or incomplete repairs to equipment causing rework and delays
 Unheated molds which require several wasted 'tests' before they will be at the
temperature to work
 Using slow precise adjustment equipment for the large coarse part of adjustment
 Lack of visual lines or benchmarks for part placement on the equipment
 Too much operator movement around the equipment during setup
 More attachment points than actually required for the forces to be constrained
 Attachment points that take more than one turn to fasten
 Any adjustments after initial setup
 Any use of experts during setup
 Any adjustments of assisting tools such as guides or switches
16Marek.Piatkowski@Rogers.com
SMED – Set-up
Reduction
Introduction
Thinkingwin, Win, WIN
Develop and “To Do” List
KAIZEN :
Objetivo :
% Actividades Atrasadas ( Delay ) Fecha de Hoy
31,3% abril 23, 2012
# Actividades Area Responsable del Éxito
Fecha
Compromiso
Fecha
Realización
Días Atraso Comentarios
1 PEDIR MP EN LA PRESENTACION COMO LAS NECESITE PRODUCCION PRODUCCION DANIEL BERUMEN 09-mar 14-mar 5 Done Close 100% 25% 50% 75% 100%
DANIEL BERUMEN YA HABLO CON CINTHYA PARA
PEDIR MP COMO LOS NECESITA PRODUCCION
2
CHECK LIST DE MATERIALES EN MAQUINA PROTOTIPO 30 MINUTOS ANTES
DE CADA CAMBIO DE PRODUCTO
PRODUCCION SUPERVISORES 09-mar 45 Delay Open 0%
LOS SUPERVISORES SERAN LOS ENCARGADOS DE
REALIZAR EL CHECK-LIST
3 MEDICION DE TIEMPOS DE CAMBIO DE PRODUCTO PRODUCCION ADRIAN 15-abr 8 Delay Open 0%
EL DIA 28 DE MARZO, ADRIAN SE LE OCUPO EN
OTRAS ACTIVIDADES POR LO TANTO NO HAY TOMA
4
VALIDACION DEL NUEVO PROCEDIMIENTO DURANTE UNA SEMANA (DEL 7
DE MARZO AL 16 DE MARZO)
PRODUCCION ADRIAN 16-mar 16-mar 0 Done Close 100% 25% 50% 75% 100%
5 MEDICION DE TIEMPOS DE LLENADO POR PRODUCTO PRODUCCION ADRIAN 15-abr 8 Delay Open 0%
EL DIA 28 DE MARZO, ADRIAN SE LE OCUPO EN
OTRAS ACTIVIDADES POR LO TANTO NO HAY TOMA
DE TIEMPOS.
6
REALIZAR PRUEBA DE LAVADO CON UN PRODUCTO CON ALTA
VISCOSIDAD
PRODUCCION DANIEL BERUMEN 09-mar 09-mar 0 Done Close 0% 25% 50% 75% 100% ES FACTIBLE ENVASAR ESTE PRODUCTO
7
CAPACITACION DEL NUEVO PROCEDIMIENTO DE LAVADO A TODO EL
PERSONAL INVOLUCRADO EN LAS MAQUINAS DE VACIADO
PRODUCCION ADRIAN 15-abr 8 Delay Open 75% 25% 50% 75%
EL DIA 28 DE MARZO, ADRIAN SE LE OCUPO EN
OTRAS ACTIVIDADES POR LO TANTO NO HAY TOMA
8 ADAPTAR SISTEMA DE ALTURAS DE BOQUILLA MANTENIMIENTO ARTURO RESENDIZ 16-mar 38 Delay Open 0%
9 ANCLAR MANGUERA PARA PURGA POR BOQUILLA MANTENIMIENTO ARTURO RESENDIZ 20-mar 20-mar 0 Done Close 100% 25% 50% 75% 100%
10
UNA VEZ APROBADO EL PROCEDIMIENTO DE LAVADO CAMBIAR EL
SISTEMA DE LAVADO EN TODAS LAS MAQUINAS ENVASADORAS QUE SE
ESTAN ESTUDIANDO
MANTENIMIENTO ARTURO RESENDIZ 21-mar 28-mar 7 Done Close 100% 25% 50% 75% 100% CONTANDO CON EL MATERIAL Y EL EQUIPO
11
CONECTOR RAPIDO, CONECTOR MACHO EN MISMA BOQUILLA DE
DESAGUE
MANTENIMIENTO ARTURO RESENDIZ 21-mar 28-mar 7 Done Close 100% 25% 50% 75% 100% ESTAN LISTAS 4 MAQUINAS DE 6
12 RECORTAR MANGUERA DE ALIMENTACION DE PRODUCTO MANTENIMIENTO ARTURO RESENDIZ 21-mar 24-mar 3 Done Close 100% 25% 50% 75% 100%
13 DEFINIR LAYOUT PARA LOCALIZACION DE ENVASADORAS. PRODUCCION DANIEL BERUMEN 14-mar 16-mar 2 Done Close 100% 25% 50% 75% 100%
14 ALMACEN DARA LA MP COMO PRODUCCION NECESITE ALMACEN CINTHYA 21-mar 21-mar 0 Done Close 100% 25% 50% 75% 100%
15 REVISAR CON PROGRAMACION UNA CORRIDA DE PRUEBA PARA CAPACITACION PRODUCCION DANIEL BERUMEN 16-mar 16-mar 0 Done Close 100% 25% 50% 75% 100%
16 HABILITAR BOQUILLAS NECESARIO PARA TODAS LAS MAQUINA MANTENIMIENTO ARTURO RESENDIZ 23-mar 30-mar 7 Done Close 0% 25% 50% 75% 100%
EL DIA 28 AUN NO HAY NINGUNA DE ESTAS
BOQUILLAS
17 LISTA DE HERRAMIENTAS NECESARIAS PARA TODAS LAS MAQUINAS PRODUCCION DANIEL BERUMEN 23-mar 23-mar 0 Done Close 0% 25% 50% 75% 100%
18 HABILITAR HERRAMIENTAS NECESARIAS PARA TODAS LAS MAQUINAS
MEJORA
CONTINUA
ANALILIA 27-mar 27 Delay Open 0%
EL DIA 28 AUN NO HAY NINGANA DE ESTAS
HERRAMIENTAS
19 CAPACITACION DE 8 OPERADORES Y CERTIFICACION DE SMED MAQUINA EVA RH OSCAR LEAL 27-abr - On Going Open 0%
20 REVISION DE CHECK LIST MAQUINA EVA 1. DESDE HOY Y HASTA EL 27 ABRIL PRODUCCION SUPERVISORES 27-abr - On Going Open 0%
21
REVISION DE TIEMPOS PROGRAMADOS VS REAL DE PRODUCCION MAQUINA EVA 1.
DESDE HOY Y HASTA EL 27 ABRIL
PRODUCCION SUPERVISORES 27-abr - On Going Open 0%
22 IMPLEMENTAR EL PIZARRON DE PRODUCCION PRODUCCION DANIEL BERUMEN 27-abr - On Going Open 0%
23 REVISAR TARIMAS QUE NUNCA FALTEN.
MEJORA
CONTINUA
ANALILIA 27-abr - On Going Open 0%
Estatus % Avance
Sem.
% Cumplimiento ( Open/Close )
50,0%
17Marek.Piatkowski@Rogers.com
SMED – Set-up
Reduction
Introduction
Thinkingwin, Win, WIN
Set-up reduction tools
18Marek.Piatkowski@Rogers.com
SMED – Set-up
Reduction
Introduction
Thinkingwin, Win, WIN
Changeover Schedule
19Marek.Piatkowski@Rogers.com
SMED – Set-up
Reduction
Introduction
Thinkingwin, Win, WIN
Test new Procedures
OPERADOR A
ACTIVIDADES
TOLVA TABLERO
MESA
MESADE
EMPAQUE
PT
KANBANMP
MANGUERASDE
ALIMENTACION
PASILLO
TARIMAS
AREADE
PATIN
LAVADO
DRENAJE
DRENAJE
E
V
A
1
2
SOPLETEADO
22 min
DURACION:
1-3
4-6
7
8
9
10-18
19-21
22-25
26
27-30
31-32
33
34-36
4 18
5 24
11 31
14 7
18 4
22 35
23 11
24 40
26 10
27 103
28 23
29 11
32 4
33 33
35 50
50 7
51 12
59 54
61 71
62 51
65 173
66 140
67 62
73 83
86 47
101 46
102 86
113 16REGULA FLUJODELPRODUCTO
INSTALA BOQUILLA LIMPIA ENMAQUINA
AJUSTA ALTURA DE BOQUILLAS
GENERA CICLODE VACIADODE AGUA PARA PURGARTOLVA
TOMA MANGUERA Y COLOCA ENBOQUILLA DE DESAGUE
GENERA UNSEXTOCICLODE LLENADO
GENERA 4CICLODE LLENADO
GENERA 5CICLODE LLENADO
GENERA SEGUNDOCICLODE LLENADODE NIVEL
GENERA TERCERCICLODE LLENADO
PRIMERAJUSTE DE CICLODE NIVELDE LLENADO
RETIRA BOQUILLA DE METALY COLOCA SIGBOQUILLA
AJUSTA TIEMPOS DE LLENADO
INICIA SEPTIMOCICLODE DESAGUE
ESPERA CORTE DE CICLODE DRENADO
DESCONECTARMANGUERA DE ALIMENTACIONDE AGUA Y DRENA MANGUERA
ESPERA CORTE DE CICLODE DRENADOY LLENADODE TOLVA
INICIA QUINTOCICLODE DESAGUE
INICIA SEXTOCICLODE DESAGUE
INICIA TERCERCICLODE DESAGUE
ESPERA CORTE DE CICLODE DRENADO
INICIA CUARTOCICLODE DESAGUE
INICIA SEGUNDOCICLODE DESAGUE
ESPERA CORTE DE CICLODE DESAGUE
INICIA CICLODE DRENADODE AGUA
AJUSTE DE TIEMPODE LAVADO
REALIZA CAMBIODE BOQUILLA PORBOQUILLA METALICA
AFLOJA ELEVADORPARA AJUSTE DE BOQUILLA
LAY OUT EVA-03
RESPONSABLE:METODO DE TRABAJO PARA CAMBIO DE
PRODUCTO
46:13 min
22:00 min
20Marek.Piatkowski@Rogers.com
SMED – Set-up
Reduction
Introduction
Thinkingwin, Win, WIN
Improve more
46:13 min
22:00 min
OPERADOR A
ACTIVIDADES
TOLVA TABLERO
MESA
MESADE
EMPAQUE
PT
KANBANMP
MANGUERASDE
ALIMENTACION
PASILLO
TARIMAS
AREADE
PATIN
LAVADO
DRENAJE
DRENAJE
E
V
A
1
2
SOPLETEADO
15:07 min
DURACION:
2
14
12 13
6
16
11
7
15 18
19
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10
9
5
4
20
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23
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CONECTAR MANGUERA A BOQUILLA PARA
PURGA
CONECTAR MANGUERA EN AGUA PARA
LLENADO DE TOLVA
ABRE VALVULA DE AGUA PARA TOLVA
HASTA QUE SE LLENA LA TOLVA
PROGRAMA TIEMPO DE LAVADO PRENDER
BOMBA (100% APERTURA DE VALVULA
RETIRAR PRODUCTO SOBRANTE (TAPA Y
BOTELLA)
CONECTAR MANGUERA PARA PURGA EN
TOLVA
PURGA VALVULA DE LA TOLVA
INTERMITENTE
ESPERA O VERIFICA LA INFORMACION DEL
SIG. PRODUCTO A ENVASAR (DATOS,
ESCURRE LA MANGUERA DE AGUA POR
VALVULA DE TOLVA
DESCONECTA MANGUERA Y CERRAR
VALVULA DE TOLVA Y LA COLOCA EN SU
INICIA CICLO DE LLENADO
ETIQUETA EL PORRON
REALIZA PURGA POR BOQUILLA EN
CUBETA DE 4 LITROS
PROGRAMA CICLO DE LLENADO
INICIA PURGA DE TOLVA POR BOQUILLA HASTA 3 CICLOS
PURGA VALVULA DE LA TOLVA
INTERMITENTE
ESPERA O LLENA REPORTE DE ORDEN DE
PLANTA TERMINADA
ABRE VALVULA DE AGUA PARA TOLVA
HASTA QUE SE LLENA LA TOLVA POR
INICIA PURGA DE TOLVA POR BOQUILLA HASTA 3 CICLOS
DESCONECTA MANGUERA DE BOQUILLA Y
LA COLOCA EN SU LUGAR
CONECTAR MANGUERA DE DESAGUE DE
TANQUES INTERMEDIOS Y ABRE VALVULA
SE CONECTA A TANQUE DE SIG.
PRODUCTO Y LE ABRE VALVULA HASTA
AJUSTA ALTURA DE BOQUILLA
AJUSTA VELOCIDAD DE BOMBA AL 100%
PURGA VALVULA DE LA TOLVA
INTERMITENTE
ESPERA O VERIFICA LA INFORMACION DEL
SIG. PRODUCTO A ENVASAR (DATOS,
ABRE VALVULA DE AGUA PARA TOLVA
HASTA QUE SE LLENA LA TOLVA POR
INICIA PURGA DE TOLVA POR BOQUILLA HASTA 3 CICLOS
29
30
31
32
33 34 35
CAMBIO DE PRODUCTO DE
(GALON NEUTROLIN A
PORRON BIOACTIV 200)
LAY OUT EVA-03
RESPONSABLE:METODO DE TRABAJO PARA CAMBIO DE
PRODUCTO
15:07 min
21Marek.Piatkowski@Rogers.com
SMED – Set-up
Reduction
Introduction
Thinkingwin, Win, WIN
Step 5 - Standardize what has been done
 Sequence external and internal processes
 Identify roles and responsibilities for each Operator
 Standardize hardware (e.g. so fewer tools are needed)
 Standardize removing and mounting tools
 Standardize removal and installation procedures
 Standardize tools required for change
 Train operators on a new process
 Re-tape the set-up to determine new set-up time
 Repeat the process
 Create parallel operations (e.g. note that with multiple operators working on the
same equipment close attention must be paid to potential safety issues)
22Marek.Piatkowski@Rogers.com
SMED – Set-up
Reduction
Introduction
Thinkingwin, Win, WIN
Standardize new Methodology
46:13 min
22:00 min
15:07 min TABLERO
MESA
MESA DE
EMPAQUE
PT
KANBAN MP
MANGUERAS DE
ALIMENTACION
PASILLO
AREA DE
PATIN
LAVADO
DRENAJE
DRENAJE
OPERADOR A
ACTIVIDADES
10min
DURACION:
1
7
2
4
3
CAMBIO DE PRODUCTO DE
(GALON LAVALOZA BIO A
GALON JABON ANTIPLOMO)
5 6
9
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
REVISION SIGUIENTE PRODUCTO A ENVASAR
RETIRAR PRODUCTO SOBRANTE (TAPA Y BOTELLA)
TRAER MP DEL SIG. PRODUCTO (TAPA Y BOTELLA)
NOTIFICA A TANQUES INTERMEDIOS QUE EMPIEZA EL CICLO DE LAVADO DE TANQUE
CONECTAR MANGUERA DE DESCARGA A BOQUILLA DE PULGADA
COLOCAR CUBETA DE 4 LITROS EN MESA PARA CAMBIO DE BOQUILLA
CAMBIO DE BOQUILLA A METALICA DE 1 "
CONECTAR MANGUERA PARA LAVADO DE TANQUE INTERMEDIO Y ABRIR VALVULA
CONECTAR MANGUERA A TUBERIA DE AGUA (TANQUE 5C)
ABRIR VALVULA (TANQUE 5C) A 3/4
DESCONECTAR LA MANGUERA DE LAVADO DE TANQUE INTERMEDIO CONECTARLA A
RECOGE HOJA DE TABLERO DE INFORMACION DE TANQUES INTERMEDIOS DEL PRODUCTO
LLEVA A SUPERVISOR LA HOJA DE TABLERO DE INFORMACION.
GENERAR TERCER CICLO DE LAVADO (30 SEG)
GENERAR SEGUNDO CICLO DE LAVADO (30 SEG) CON BOMBA ENCENDIDA EN 5
PROGRAMAR VELOCIDAD DE LA BOMBA EN 5
RECIRCULAR DE 5 A 10 SEGUNDOS
PROGRAMAR PRIMER CICLO DE LAVADO POR GRAVEDAD (30 SEG)
ENCENDER BOMBA
CONECTAR MANGUERA A SIGUIENTE PRODUCTO A ENVASAR
ABRIR VALVUA DE SIG. PRODUCTO
GENERA CUARTO CICLO DE LAVADO
CERRAR VALVULA DE AGUA
ESCURRIR MANGUERA DE AGUA
DESCONECTAR MANGUERA DE DESAGUE DE BOQUILLA
AL TERMINAR EL TERCER CICLO DE LAVADO APAGAR LA BOMBA
DESCONECTAR MANGUERA DE AGUA
ETIQUETAR EL ENVASE
REALIZA PURGA POR BOQUILLA EN CUBETA DE 4 LITROS
INICIA CICLO DE LLENADO
RECIRCULAR DE 5 A 10 SEGUNDOS
CERRAR VALVULA DE BOQUILLA
AJUSTA VELOCIDAD DE BOMBA SEGÚN PRODUCTO A ENVASAR
AJUSTA ALTURA DE BOQUILLA
PROGRAMA CICLO DE LLENADO
8
10
11
1213
14 15 16 17 18 19
20 21 22
23 24
25
26 27
28 29
30-35
METODO ACTUAL LAY OUT EVA-03
RESPONSABLE:METODO DE TRABAJO PARA CAMBIO DE
PRODUCTO
10:00 min
23Marek.Piatkowski@Rogers.com
SMED – Set-up
Reduction
Introduction
Thinkingwin, Win, WIN
Changeover
Improvements
24Marek.Piatkowski@Rogers.com
SMED – Set-up
Reduction
Introduction
Thinkingwin, Win, WIN
Changeover
Improvements
ESP
25Marek.Piatkowski@Rogers.com
SMED – Set-up
Reduction
Introduction
Thinkingwin, Win, WIN
Changing the World. One Transformation at a time
This presentation is an intellectual property of W3 Group Canada Inc.
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W3 Group Canada Inc.
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Thinkingwin, Win, WIN
26Marek.Piatkowski@Rogers.com
SMED – Set-up
Reduction
Introduction
Thinkingwin, Win, WIN
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SMED or Single Minute Exchange of Dies and Set-up Reduction Process

  • 1. 1Marek.Piatkowski@Rogers.com SMED – Set-up Reduction Introduction Thinkingwin, Win, WIN SMED – Changeover Times Introduction Marek Piatkowski – January 2017 Thinkingwin, Win, WIN
  • 2. 2Marek.Piatkowski@Rogers.com SMED – Set-up Reduction Introduction Thinkingwin, Win, WIN Introduction - Marek Piatkowski  Professional Background  Toyota Motor Manufacturing Canada (TMMC) - Cambridge, Ontario from 1987-1994  TPS/Lean Transformation Consulting - since 1994  Professional Affiliations  TWI Network – John Shook, Founder  Lean Enterprise Institute (LEI) – Jim Womack  Lean Enterprise Academy (LEA) – Daniel Jones  CCM/CAINTRA – Monterrey, Mexico  SME, AME, ASQ, CME  Lean Manufacturing Solutions - Toronto, Canada http://twi-network.com
  • 4. 4Marek.Piatkowski@Rogers.com SMED – Set-up Reduction Introduction Thinkingwin, Win, WIN What is SMED?  Single-Minute Exchange of Die (SMED) is one of the many lean production methods for reducing waste in a manufacturing process.  The name Single-Minute Exchange of Dies comes from the goal of reducing changeover times to the “single” digits (i.e. less than 10 minutes).  SMED was developed by Shigeo Shingo, a Japanese industrial engineer who was extraordinarily successful in helping companies dramatically reduce their changeover times in a Stamping Press shop.  His pioneering work led to documented reductions in changeover times averaging 94% (e.g. from 90 minutes to less than 5 minutes) across a wide range of companies.  The SMED process focuses on making as many elements as possible external, and simplifying and streamlining all elements.
  • 5. 5Marek.Piatkowski@Rogers.com SMED – Set-up Reduction Introduction Thinkingwin, Win, WIN What is Set-up (Changeover) Reduction?  SMED was developed at Toyota in a Press shop to exchange stamping dies.  Many operations, for example paint, assembly, welding, testing do not use dies, but they do face production model (product type) changes.  Set-up (Changeovers) reduction process is a systematic approach to reduce stop- time of any machine or a process during a model or product change  Set-up reduction is a methodology for improving a process of converting a manufacturing process from running the current product (model) to running the next product (model)  Set-up definition:  The amount of time taken to change over a piece of equipment from the last piece of a production lot to the first good piece of the next production lot.
  • 6. 6Marek.Piatkowski@Rogers.com SMED – Set-up Reduction Introduction Thinkingwin, Win, WIN Why do we need to reduce Set-up times?  Reduce equipment downtime  Speed and flexibility:  To shorten lead times - increases scheduling flexibility/capacity  To produce less Inventory – frequent small batch production  Shorter runs  Quicker response – increases production flexibility  Quicker setups  To benefit Operators  Standardized process - Safer changeovers  Less clutter  Few tools to keep track of  Less adjustments means less chance for errors
  • 7. 7Marek.Piatkowski@Rogers.com SMED – Set-up Reduction Introduction Thinkingwin, Win, WIN Typical Set-up Activities 30% - Preparing and storing materials, dies, fixtures, parts and tools 5% - Clamping and removing parts, dies and tools 30% 5% 15% - centering and determining dimensions of tooling 15% 50% - Trial processing, machine programming or settings, after- process adjustment and checking 50%
  • 8. 8Marek.Piatkowski@Rogers.com SMED – Set-up Reduction Introduction Thinkingwin, Win, WIN Set-up Reduction Process 1. Video tape the set-up 2. Separate internal and external activities 3. Shift internal activities to external activities 4. Improve all work methods of the operation 5. Standardize what has been done
  • 9. 9Marek.Piatkowski@Rogers.com SMED – Set-up Reduction Introduction Thinkingwin, Win, WIN Step 1 - Video tape the set-up  Capture all activities that occur  Focus on the machine, do not follow operators  Do not turn off the video recorder for any reason during the set-up  Get as much detail as possible  Identify all parts produced on the equipment  Select 2-3 part numbers for setup observation  Identify external items needed for each part’s setup  Create an external items checklist  Gather fixtures, tools, and part drawings  Make notes at any time (Voice-over, Notebook, etc.)  Identify work elements  Map process flow  Make time observations
  • 11. 11Marek.Piatkowski@Rogers.com SMED – Set-up Reduction Introduction Thinkingwin, Win, WIN Document a current process 1 2 4 5 6 7 8 9 10 11 12 13 14 15 17 18 20 21 22 23 24 25 VACIA MANGUERA DE PRODUCTO QUE QUEDA EN LA LINEA DE ALIMENTACION AFLOJA ELEVADOR PARA AJUSTE DE BOQUILLA ESPERA CORTE DE CICLO DE DRENADO LIMPIA MESA TIRA BOTELLAS SOBRANTES DE CORRIDA ANTERIOR TOMA MANGUERA EN SALIDA DE DRENAJE ORGANIZANDO PARA EL CAMBIO CON OPERADOR B CAMINA POR MANGUERA A EVA 12 REALIZA CAMBIO DE BOQUILLA POR BOQUILLA METALICA RETIRA CUBETA DE PURGA DE MAQUINA REAPRIETA TORNILLOS DE ELEVADOR CONECTA LA MANGUERA A TUBERIA DE AGUA ESPERA A LLENARSE LA TOLVA DE AGUA TOMA TRAPEADOR Y LIMPIA AREA AJUSTA TIEMPO DEL CICLO DE DESAGUE INICIA TERCER CICLO DE DESAGUE ESPERA CORTE DE CICLO DE DESAGUE AJUSTE DE TIEMPO DE LAVADO RETIRA ENVASES DE CORRIDA ANTERIOR A KANBAN REAJUSTE DE CICLO DE DESAGUE INICIA CICLO DE DRENADO DE AGUA REAJUSTA ALTURA DE ELEVADOR INICIA SEGUNDO CICLO DE DESAGUE OPERADOR A ACTIVIDADES TOLVA TABLERO MESA MESADE EMPAQUE PT KANBANMP MANGUERASDE ALIMENTACION PASILLO TARIMAS AREADE PATIN LAVADO DRENAJE DRENAJE 2 7 8 5 6 1 4 14 10 12 15 13 11 9 17 21 22 20 18 23 25 24 E V A 1 2 SOPLETEADO 46:13 min DURACION: METODO ANTERIOR LAY OUT EVA-01 METODO DE TRABAJO PARA CAMBIO DE PRODUCTO RESPONSABLE: 46:13 min
  • 12. 12Marek.Piatkowski@Rogers.com SMED – Set-up Reduction Introduction Thinkingwin, Win, WIN Step 2 - Separate internal and external activities  Analyze the video tape:  Use the “Set-up time breakdown sheet” to list all activities that take place  How many adjustments?  How many bolts or clamps are loosened / tightened?  How many different tools are used?  What’s the travel distance to get tools / materials?  How many pieces of paperwork are used?  How many checks are conducted?  How many shots (injection molding), cuts (machining), or passes (grinding) are done on a good part?  Determine if the activities are “External” or “Internal”  External activities are ones that are done while the machine is running production  Internal activities are ones that are done while the machine is idle (stopped)
  • 13. 13Marek.Piatkowski@Rogers.com SMED – Set-up Reduction Introduction Thinkingwin, Win, WIN Step 3 - Shift internal activities to external activities  Determine which activities could be done while the machine is in production  Brainstorm potential solutions  Pre-setup activities (before the machine stops):  Tools cleaned, sharpened, etc …  Gauges preset  Materials transported / sequenced  Tools / fixtures staged  Post-Set-up activities (after new production started:  Setup for the current batch is complete  Clean, inspect, repair (if needed) tools and fixtures  Store all items in assigned locations
  • 14. 14Marek.Piatkowski@Rogers.com SMED – Set-up Reduction Introduction Thinkingwin, Win, WIN Step 4 - Improve all work methods of the operation  Brainstorm possible solutions to the set-up process  Eliminate adjustments  Standardize Clamping Height  Position all materials near point-of-use  Do we need a set-up cart?  Develop an “Action Plan”  Try different methods – Test Runs  Eliminate bolts (e.g. use quick release mechanisms or other types of functional clamps)  Eliminate unnecessary motion (e.g. reorganize the work space)  Eliminate waiting (e.g. make first article inspection a high priority for QA)  Mechanization is normally considered as a last resort
  • 15. 15Marek.Piatkowski@Rogers.com SMED – Set-up Reduction Introduction Thinkingwin, Win, WIN SMED Process Improvements – what to look for  Shortages, mistakes, inadequate verification of equipment causing delays and can be avoided by check tables, especially visual ones, and setup on an intermediary jig  Inadequate or incomplete repairs to equipment causing rework and delays  Unheated molds which require several wasted 'tests' before they will be at the temperature to work  Using slow precise adjustment equipment for the large coarse part of adjustment  Lack of visual lines or benchmarks for part placement on the equipment  Too much operator movement around the equipment during setup  More attachment points than actually required for the forces to be constrained  Attachment points that take more than one turn to fasten  Any adjustments after initial setup  Any use of experts during setup  Any adjustments of assisting tools such as guides or switches
  • 16. 16Marek.Piatkowski@Rogers.com SMED – Set-up Reduction Introduction Thinkingwin, Win, WIN Develop and “To Do” List KAIZEN : Objetivo : % Actividades Atrasadas ( Delay ) Fecha de Hoy 31,3% abril 23, 2012 # Actividades Area Responsable del Éxito Fecha Compromiso Fecha Realización Días Atraso Comentarios 1 PEDIR MP EN LA PRESENTACION COMO LAS NECESITE PRODUCCION PRODUCCION DANIEL BERUMEN 09-mar 14-mar 5 Done Close 100% 25% 50% 75% 100% DANIEL BERUMEN YA HABLO CON CINTHYA PARA PEDIR MP COMO LOS NECESITA PRODUCCION 2 CHECK LIST DE MATERIALES EN MAQUINA PROTOTIPO 30 MINUTOS ANTES DE CADA CAMBIO DE PRODUCTO PRODUCCION SUPERVISORES 09-mar 45 Delay Open 0% LOS SUPERVISORES SERAN LOS ENCARGADOS DE REALIZAR EL CHECK-LIST 3 MEDICION DE TIEMPOS DE CAMBIO DE PRODUCTO PRODUCCION ADRIAN 15-abr 8 Delay Open 0% EL DIA 28 DE MARZO, ADRIAN SE LE OCUPO EN OTRAS ACTIVIDADES POR LO TANTO NO HAY TOMA 4 VALIDACION DEL NUEVO PROCEDIMIENTO DURANTE UNA SEMANA (DEL 7 DE MARZO AL 16 DE MARZO) PRODUCCION ADRIAN 16-mar 16-mar 0 Done Close 100% 25% 50% 75% 100% 5 MEDICION DE TIEMPOS DE LLENADO POR PRODUCTO PRODUCCION ADRIAN 15-abr 8 Delay Open 0% EL DIA 28 DE MARZO, ADRIAN SE LE OCUPO EN OTRAS ACTIVIDADES POR LO TANTO NO HAY TOMA DE TIEMPOS. 6 REALIZAR PRUEBA DE LAVADO CON UN PRODUCTO CON ALTA VISCOSIDAD PRODUCCION DANIEL BERUMEN 09-mar 09-mar 0 Done Close 0% 25% 50% 75% 100% ES FACTIBLE ENVASAR ESTE PRODUCTO 7 CAPACITACION DEL NUEVO PROCEDIMIENTO DE LAVADO A TODO EL PERSONAL INVOLUCRADO EN LAS MAQUINAS DE VACIADO PRODUCCION ADRIAN 15-abr 8 Delay Open 75% 25% 50% 75% EL DIA 28 DE MARZO, ADRIAN SE LE OCUPO EN OTRAS ACTIVIDADES POR LO TANTO NO HAY TOMA 8 ADAPTAR SISTEMA DE ALTURAS DE BOQUILLA MANTENIMIENTO ARTURO RESENDIZ 16-mar 38 Delay Open 0% 9 ANCLAR MANGUERA PARA PURGA POR BOQUILLA MANTENIMIENTO ARTURO RESENDIZ 20-mar 20-mar 0 Done Close 100% 25% 50% 75% 100% 10 UNA VEZ APROBADO EL PROCEDIMIENTO DE LAVADO CAMBIAR EL SISTEMA DE LAVADO EN TODAS LAS MAQUINAS ENVASADORAS QUE SE ESTAN ESTUDIANDO MANTENIMIENTO ARTURO RESENDIZ 21-mar 28-mar 7 Done Close 100% 25% 50% 75% 100% CONTANDO CON EL MATERIAL Y EL EQUIPO 11 CONECTOR RAPIDO, CONECTOR MACHO EN MISMA BOQUILLA DE DESAGUE MANTENIMIENTO ARTURO RESENDIZ 21-mar 28-mar 7 Done Close 100% 25% 50% 75% 100% ESTAN LISTAS 4 MAQUINAS DE 6 12 RECORTAR MANGUERA DE ALIMENTACION DE PRODUCTO MANTENIMIENTO ARTURO RESENDIZ 21-mar 24-mar 3 Done Close 100% 25% 50% 75% 100% 13 DEFINIR LAYOUT PARA LOCALIZACION DE ENVASADORAS. PRODUCCION DANIEL BERUMEN 14-mar 16-mar 2 Done Close 100% 25% 50% 75% 100% 14 ALMACEN DARA LA MP COMO PRODUCCION NECESITE ALMACEN CINTHYA 21-mar 21-mar 0 Done Close 100% 25% 50% 75% 100% 15 REVISAR CON PROGRAMACION UNA CORRIDA DE PRUEBA PARA CAPACITACION PRODUCCION DANIEL BERUMEN 16-mar 16-mar 0 Done Close 100% 25% 50% 75% 100% 16 HABILITAR BOQUILLAS NECESARIO PARA TODAS LAS MAQUINA MANTENIMIENTO ARTURO RESENDIZ 23-mar 30-mar 7 Done Close 0% 25% 50% 75% 100% EL DIA 28 AUN NO HAY NINGUNA DE ESTAS BOQUILLAS 17 LISTA DE HERRAMIENTAS NECESARIAS PARA TODAS LAS MAQUINAS PRODUCCION DANIEL BERUMEN 23-mar 23-mar 0 Done Close 0% 25% 50% 75% 100% 18 HABILITAR HERRAMIENTAS NECESARIAS PARA TODAS LAS MAQUINAS MEJORA CONTINUA ANALILIA 27-mar 27 Delay Open 0% EL DIA 28 AUN NO HAY NINGANA DE ESTAS HERRAMIENTAS 19 CAPACITACION DE 8 OPERADORES Y CERTIFICACION DE SMED MAQUINA EVA RH OSCAR LEAL 27-abr - On Going Open 0% 20 REVISION DE CHECK LIST MAQUINA EVA 1. DESDE HOY Y HASTA EL 27 ABRIL PRODUCCION SUPERVISORES 27-abr - On Going Open 0% 21 REVISION DE TIEMPOS PROGRAMADOS VS REAL DE PRODUCCION MAQUINA EVA 1. DESDE HOY Y HASTA EL 27 ABRIL PRODUCCION SUPERVISORES 27-abr - On Going Open 0% 22 IMPLEMENTAR EL PIZARRON DE PRODUCCION PRODUCCION DANIEL BERUMEN 27-abr - On Going Open 0% 23 REVISAR TARIMAS QUE NUNCA FALTEN. MEJORA CONTINUA ANALILIA 27-abr - On Going Open 0% Estatus % Avance Sem. % Cumplimiento ( Open/Close ) 50,0%
  • 19. 19Marek.Piatkowski@Rogers.com SMED – Set-up Reduction Introduction Thinkingwin, Win, WIN Test new Procedures OPERADOR A ACTIVIDADES TOLVA TABLERO MESA MESADE EMPAQUE PT KANBANMP MANGUERASDE ALIMENTACION PASILLO TARIMAS AREADE PATIN LAVADO DRENAJE DRENAJE E V A 1 2 SOPLETEADO 22 min DURACION: 1-3 4-6 7 8 9 10-18 19-21 22-25 26 27-30 31-32 33 34-36 4 18 5 24 11 31 14 7 18 4 22 35 23 11 24 40 26 10 27 103 28 23 29 11 32 4 33 33 35 50 50 7 51 12 59 54 61 71 62 51 65 173 66 140 67 62 73 83 86 47 101 46 102 86 113 16REGULA FLUJODELPRODUCTO INSTALA BOQUILLA LIMPIA ENMAQUINA AJUSTA ALTURA DE BOQUILLAS GENERA CICLODE VACIADODE AGUA PARA PURGARTOLVA TOMA MANGUERA Y COLOCA ENBOQUILLA DE DESAGUE GENERA UNSEXTOCICLODE LLENADO GENERA 4CICLODE LLENADO GENERA 5CICLODE LLENADO GENERA SEGUNDOCICLODE LLENADODE NIVEL GENERA TERCERCICLODE LLENADO PRIMERAJUSTE DE CICLODE NIVELDE LLENADO RETIRA BOQUILLA DE METALY COLOCA SIGBOQUILLA AJUSTA TIEMPOS DE LLENADO INICIA SEPTIMOCICLODE DESAGUE ESPERA CORTE DE CICLODE DRENADO DESCONECTARMANGUERA DE ALIMENTACIONDE AGUA Y DRENA MANGUERA ESPERA CORTE DE CICLODE DRENADOY LLENADODE TOLVA INICIA QUINTOCICLODE DESAGUE INICIA SEXTOCICLODE DESAGUE INICIA TERCERCICLODE DESAGUE ESPERA CORTE DE CICLODE DRENADO INICIA CUARTOCICLODE DESAGUE INICIA SEGUNDOCICLODE DESAGUE ESPERA CORTE DE CICLODE DESAGUE INICIA CICLODE DRENADODE AGUA AJUSTE DE TIEMPODE LAVADO REALIZA CAMBIODE BOQUILLA PORBOQUILLA METALICA AFLOJA ELEVADORPARA AJUSTE DE BOQUILLA LAY OUT EVA-03 RESPONSABLE:METODO DE TRABAJO PARA CAMBIO DE PRODUCTO 46:13 min 22:00 min
  • 20. 20Marek.Piatkowski@Rogers.com SMED – Set-up Reduction Introduction Thinkingwin, Win, WIN Improve more 46:13 min 22:00 min OPERADOR A ACTIVIDADES TOLVA TABLERO MESA MESADE EMPAQUE PT KANBANMP MANGUERASDE ALIMENTACION PASILLO TARIMAS AREADE PATIN LAVADO DRENAJE DRENAJE E V A 1 2 SOPLETEADO 15:07 min DURACION: 2 14 12 13 6 16 11 7 15 18 19 8 10 9 5 4 20 21 22 23 24 2 4 5 6 7 8 9 10 11 12 13 14 15 16 18 19 20 21 22 23 24 29 30 31 32 33 34 35 CONECTAR MANGUERA A BOQUILLA PARA PURGA CONECTAR MANGUERA EN AGUA PARA LLENADO DE TOLVA ABRE VALVULA DE AGUA PARA TOLVA HASTA QUE SE LLENA LA TOLVA PROGRAMA TIEMPO DE LAVADO PRENDER BOMBA (100% APERTURA DE VALVULA RETIRAR PRODUCTO SOBRANTE (TAPA Y BOTELLA) CONECTAR MANGUERA PARA PURGA EN TOLVA PURGA VALVULA DE LA TOLVA INTERMITENTE ESPERA O VERIFICA LA INFORMACION DEL SIG. PRODUCTO A ENVASAR (DATOS, ESCURRE LA MANGUERA DE AGUA POR VALVULA DE TOLVA DESCONECTA MANGUERA Y CERRAR VALVULA DE TOLVA Y LA COLOCA EN SU INICIA CICLO DE LLENADO ETIQUETA EL PORRON REALIZA PURGA POR BOQUILLA EN CUBETA DE 4 LITROS PROGRAMA CICLO DE LLENADO INICIA PURGA DE TOLVA POR BOQUILLA HASTA 3 CICLOS PURGA VALVULA DE LA TOLVA INTERMITENTE ESPERA O LLENA REPORTE DE ORDEN DE PLANTA TERMINADA ABRE VALVULA DE AGUA PARA TOLVA HASTA QUE SE LLENA LA TOLVA POR INICIA PURGA DE TOLVA POR BOQUILLA HASTA 3 CICLOS DESCONECTA MANGUERA DE BOQUILLA Y LA COLOCA EN SU LUGAR CONECTAR MANGUERA DE DESAGUE DE TANQUES INTERMEDIOS Y ABRE VALVULA SE CONECTA A TANQUE DE SIG. PRODUCTO Y LE ABRE VALVULA HASTA AJUSTA ALTURA DE BOQUILLA AJUSTA VELOCIDAD DE BOMBA AL 100% PURGA VALVULA DE LA TOLVA INTERMITENTE ESPERA O VERIFICA LA INFORMACION DEL SIG. PRODUCTO A ENVASAR (DATOS, ABRE VALVULA DE AGUA PARA TOLVA HASTA QUE SE LLENA LA TOLVA POR INICIA PURGA DE TOLVA POR BOQUILLA HASTA 3 CICLOS 29 30 31 32 33 34 35 CAMBIO DE PRODUCTO DE (GALON NEUTROLIN A PORRON BIOACTIV 200) LAY OUT EVA-03 RESPONSABLE:METODO DE TRABAJO PARA CAMBIO DE PRODUCTO 15:07 min
  • 21. 21Marek.Piatkowski@Rogers.com SMED – Set-up Reduction Introduction Thinkingwin, Win, WIN Step 5 - Standardize what has been done  Sequence external and internal processes  Identify roles and responsibilities for each Operator  Standardize hardware (e.g. so fewer tools are needed)  Standardize removing and mounting tools  Standardize removal and installation procedures  Standardize tools required for change  Train operators on a new process  Re-tape the set-up to determine new set-up time  Repeat the process  Create parallel operations (e.g. note that with multiple operators working on the same equipment close attention must be paid to potential safety issues)
  • 22. 22Marek.Piatkowski@Rogers.com SMED – Set-up Reduction Introduction Thinkingwin, Win, WIN Standardize new Methodology 46:13 min 22:00 min 15:07 min TABLERO MESA MESA DE EMPAQUE PT KANBAN MP MANGUERAS DE ALIMENTACION PASILLO AREA DE PATIN LAVADO DRENAJE DRENAJE OPERADOR A ACTIVIDADES 10min DURACION: 1 7 2 4 3 CAMBIO DE PRODUCTO DE (GALON LAVALOZA BIO A GALON JABON ANTIPLOMO) 5 6 9 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 REVISION SIGUIENTE PRODUCTO A ENVASAR RETIRAR PRODUCTO SOBRANTE (TAPA Y BOTELLA) TRAER MP DEL SIG. PRODUCTO (TAPA Y BOTELLA) NOTIFICA A TANQUES INTERMEDIOS QUE EMPIEZA EL CICLO DE LAVADO DE TANQUE CONECTAR MANGUERA DE DESCARGA A BOQUILLA DE PULGADA COLOCAR CUBETA DE 4 LITROS EN MESA PARA CAMBIO DE BOQUILLA CAMBIO DE BOQUILLA A METALICA DE 1 " CONECTAR MANGUERA PARA LAVADO DE TANQUE INTERMEDIO Y ABRIR VALVULA CONECTAR MANGUERA A TUBERIA DE AGUA (TANQUE 5C) ABRIR VALVULA (TANQUE 5C) A 3/4 DESCONECTAR LA MANGUERA DE LAVADO DE TANQUE INTERMEDIO CONECTARLA A RECOGE HOJA DE TABLERO DE INFORMACION DE TANQUES INTERMEDIOS DEL PRODUCTO LLEVA A SUPERVISOR LA HOJA DE TABLERO DE INFORMACION. GENERAR TERCER CICLO DE LAVADO (30 SEG) GENERAR SEGUNDO CICLO DE LAVADO (30 SEG) CON BOMBA ENCENDIDA EN 5 PROGRAMAR VELOCIDAD DE LA BOMBA EN 5 RECIRCULAR DE 5 A 10 SEGUNDOS PROGRAMAR PRIMER CICLO DE LAVADO POR GRAVEDAD (30 SEG) ENCENDER BOMBA CONECTAR MANGUERA A SIGUIENTE PRODUCTO A ENVASAR ABRIR VALVUA DE SIG. PRODUCTO GENERA CUARTO CICLO DE LAVADO CERRAR VALVULA DE AGUA ESCURRIR MANGUERA DE AGUA DESCONECTAR MANGUERA DE DESAGUE DE BOQUILLA AL TERMINAR EL TERCER CICLO DE LAVADO APAGAR LA BOMBA DESCONECTAR MANGUERA DE AGUA ETIQUETAR EL ENVASE REALIZA PURGA POR BOQUILLA EN CUBETA DE 4 LITROS INICIA CICLO DE LLENADO RECIRCULAR DE 5 A 10 SEGUNDOS CERRAR VALVULA DE BOQUILLA AJUSTA VELOCIDAD DE BOMBA SEGÚN PRODUCTO A ENVASAR AJUSTA ALTURA DE BOQUILLA PROGRAMA CICLO DE LLENADO 8 10 11 1213 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30-35 METODO ACTUAL LAY OUT EVA-03 RESPONSABLE:METODO DE TRABAJO PARA CAMBIO DE PRODUCTO 10:00 min
  • 25. 25Marek.Piatkowski@Rogers.com SMED – Set-up Reduction Introduction Thinkingwin, Win, WIN Changing the World. One Transformation at a time This presentation is an intellectual property of W3 Group Canada Inc. No parts of this document can be copied or reproduced without written permission from: Marek Piatkowski W3 Group Canada Inc. iPhone: 416-235-2631 Cell: 248-207-0416 Marek.Piatkowski@rogers.com http://twi-network.com Thinkingwin, Win, WIN
  • 26. 26Marek.Piatkowski@Rogers.com SMED – Set-up Reduction Introduction Thinkingwin, Win, WIN Presentations in this Workshop 1. Log in to: www.slideshare.net 2. Type in my name in search area: Marek Piatkowski 3. Select a presentation you want to see 4. Learn and Enjoy