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Set-up Reduction / Quick
  Change Over / SMED

 Work smarter not harder, do things
  quicker & better and add value

       Anand Subramaniam
“To the man who only has a hammer, everything
     he encounters begins to look like a nail.”

                                 - Abraham Maslow




                                                  2
Highlights

 Definition & Terms

 Why, What, Where…How?

 Implementation Roadmap




                             3
Definition & Terms
Shigeo Shingo ..believed that


                                        Shingo explains why set-
                                        up reduction is critical to
                                        TPS – the principle behind
                                        the tool:
any set-up
                                        “Provide the customer’s
  time can                              (internal and external
be reduced                              customer) exact
     by                                 requirement immediately
 59/60ths!                              with perfect quality.”


                   Productivity Press
                   ISBN 0-915299-03-8


                                                                5
SMED Vs. OTED (OTC)

 SMED (Single Minute Exchange of Die)
   Refers to a goal of reducing setup time to a
    single digit time or <10 minutes


 OTED (OTC) One Touch Exchange of Die
  / One Touch Changeover
   Refers to a goal of reducing setup time to <1
    minute


                                                    6
Set-up - Definition
Ramp down period
                                     Ramp up period
                   Set-up
                    Time
 Output




                   Production Loss




                                                      Time



                                                             7
Set-up - Definition

Last                          First
Good                          Good
Piece                         Piece




         Total elapsed Time

                                      8
Why, What, Where…How?
How is this reduction possible?




                                  10
Set-up Reduction - Goal



  Zero Set-up
            or
Eliminate Set-up
                            11
Set-up Reduction…

        Is NOT                                Is
• A program to eliminate set-    • A tool (like many) to reduce
  up people                        waste and excessive time

• A panacea to overcome poor     • A low-cost method to
  management or poor               achieve increased capacity
  process layouts                  from existing equipment

• A requirement to spend large   • A process to reduce lot sizes
  capital investment to attain     and improve product mix
  significant benefits
                                 • A cross-functional team
                                   approach to problem-solving



                                                                   12
Set-up Reduction – Bigger Picture
 In order to reduce lead time

 It is necessary to reduce lot size

 Which in turn reduces work in process

 To do this, you must reduce set-up time


                                            13
Set-up Reduction – Typical Application
 Processes making a high variety of end items

 Processes using high cost components (greater
  benefits of inventory reduction)

 Capacity bottleneck operations
   avoids purchase of new equipment
   avoids overtime
   better customer order fill
   quicker response time

                                                 14
Set-up Reduction – Traditional Practice

 Material movement           Defects or missing            Defective tooling,
   occurs after the           equipment noticed              fixtures, setup
  machine is turned           when the machine              instruments are
          off                     is running                noticed, after the
                                                           machine is turned
                                                                    on
• Completed products        • Setup tooling delivered
  are transferred to next     after the changeover
  operation                   has begun                   • The operator notices
                                                            that equipment is
• Raw material is moved     • Defective product             missing tools etc after
  after the machine is        identified after internal     internal setup has
  stopped                     setup has begun               begun




                                                                                  15
Set-up Reduction - Benefits
        Trial processing                                          Improved customer service
     eliminated & material                                                  levels
        waste reduced
                                         Less adjustment
                                           less errors                        Fewer shortages and
    Operating
   conditions                                                                     stock-outs
   prepared in
 advance which
helps to stabilise
 product quality                                                                Improved machine
                                             Benefits                          efficiency & level out
                                                                                     production
    Increased
    scheduling
    flexibility /
     capacity                                                                               Labour
                                                   Increased                                utilised
                                                 manf. process                             effectively
                              On hand             flexibility &
                             inventory              capacity               Reduced
 Improved                    reduction                                  overall Cost-of-
 cash flow                                                                  Quality


                                                                                                     16
Set-up Reduction - Outcomes

 Happy                       Increased    Increased
 Happy                                                   Improved
                Reduced      capacity /    flexibility
custome
customer        lot sizes     produc-       through
                                                         idle asset
    r                                                      usage
                                tivity    simplicity



Improved
Improve                                                   Set-up /
tool and
 tool and                                                 change-
 product
product
                            Outcomes                     over time
  design                                                 eliminated
 design


Improved
Improve                                                  Improved
 mainten-                                 Reduced
mainten-        Reduced      Reduced                      material
  ance                                    inventory
  ance          lead time     scrap                       flow and
  costs                                     costs
 costs                                                      usage



                                                                 17
Set-up Reduction – Critical Success Factors
                                                   Operators / set-up
 Elimination of waste                               people are the
                                                     owners of the
                               Small lot size       process and its
                                production              results
  Training for
 operators and
     team                                             5S and Visual
                                                     Control programs

Flow Charting
                                    CSF
 current and                                                  Increase
  proposed                                                  flexibility in
   process                                                  equipment,
                                                             processes
                                        Focus on            and people
                                       equipment
    Simple              Team             up-time     Cross-
      job               work                       functional
   changes
                                                      team

                                                                             18
Set-up Goals – Your Mandate


 Target 50% Reduction First
  Time

 Continuous Improvement
  Target 20% per year thereafter

                                   19
Implementation Roadmap
Set-up Reduction - Implementation

     Kaizen                                   ‘SMED’ / ‘QCO’




              Objective: Faster Changeovers
                   (Set-Up Reduction)




>50% Improvement                          Low cost




                                                               21
Set-up Reduction – Implementation
                        Start 6S,
                       observe &
                      document the
                      current set-up
                          time &
                         process

                                        Identify &
        Standardise                      separate
       the new set-                    Internal and
       up procedure                      External
                                           tasks




       Observe and
                                       Eliminate and
       document the
                                       / or Improve
        new set-up
                                         each task
         process

                        Externalise
                      tasks that can
                        be external
                            and
                        streamline
                       internal task




                                                       22
Set-up – Current Observation
 Identify bottleneck process & the machine

 Form cross functional Kaizen team (include shop floor)

 Observe & video record the current set-up process

 Capture start & end time for each time activity / category
  (use Pareto chart)

 Identify counter measures that can be implemented with
  procedural changes to existing fixtures / tool / dies
                                                           23
Set-up Reduction - Counter Measures
 Review observation & video with the team for
     Internal vs. External
     Value Added Vs Non-Value Added
     Normal vs. Abnormal
     Types of Waste
     Housekeeping (6 S & POUS)
     Work flow (Spaghetti Chart)


 Brainstorm ideas for improvement

                                                 24
Set up Reduction - Types


          External                         Internal
         Executed                         Executed
         while the                        while the
         machine is                       machine is
         operating                         stopped

Preparing tooling for the next set-up   Removing dies and tooling

                                                                    25
Set-up – Time Typically Spent

                       Prepare &
                   perform functional
                     checks, 30%
Run first part &
 adjust, 50%

                     Prepare machine
                     for change over,
                           15%




                      Actual change
                        over, 5%

                                        26
Set-up Reduction - Checklist




                               27
Set-up - Data Collection




                           28
Set-up – Internal & External

 Convert as much of the internal set up to
  the external set up

 Eliminate or reduce the internal and
  external set up

 Eliminate fine tuning and adjustment
  process.
                                              29
Set-up Reduction - Zero
                                    Reduce /     Repeat
 Measure     Separate    Convert
                                    Eliminate    till Zero




            External    External

External                           External
  and                                           External
                        Internal
Internal


            Internal
                        Internal
                                    Internal



                                                             30
Set-up Reduction – Reduce / Eliminate

  Prepare           (Dis)Mount          Centre / Align     Trial Run / Adj.



                                                             (Re) Adjusting
                                                           the equipment to
   Finding         Taking tooling off     (Re) Aligning     run according to
materials, jigs,        / on the        equipment to run         specs
 gauges, etc          equipment           the next part
                                                            Could take 40 ~
                                                            60% of the set-
Could take 20~      Could take 5 ~      Could take 10 ~     up process time
30% of the set-    15% of the set-      20% of the set-
up process time    up process time      up process time     Focusing here
                                                            leads to set-up
                                                           reduction times


                                                                              31
Set-up – Improvement Plan
 SOP – SMED & 6S              Standardise tooling

 Use quick fasteners          Document time savings

 Standardise the external     SOP for machine shut
  set-up actions                down or when running

 Minor modification to the    Internal to external tooling
  existing fixtures             attachment

 Point of Use Storage         Visual & Audit Checklist
                                                           32
Set-up Reduction - Ideas




                           33
Set-up Reduction – Standards



     Standards are
                                      Defects or missing
                                       equipment noticed
                                                                Defective tooling, fixtures,
Material movement occurs              when the machine is
                                                                   setup instruments are
    after the machine is                    running
                                                                     noticed, after the
          turned off
                                                                   machine is turned on


   standard: they are
• Completed products are
  transferred to next operation

• Raw material is moved after
                                  • Setup tooling delivered
                                    after the changeover
                                    has begun
                                                                • The operator notices that
                                                                  equipment is missing
                                                                  tools etc after internal
                                  • Defective product


      NOT flexible
  the machine is stopped                                          setup has begun
                                    identified after internal
                                    setup has begun




                                                                                          34
Standard Operating Procedure (SOP)




                                     35
Set-up Reduction - Repeat
   Input

       Last set-up reduction Kaizen (updated SOP, checklist, work
        instructions, trained team)

   Process

       Video tape the new set-up procedure and record the set-up time for
        each element

       Generate ideas and implement the improvement

 Output

     Revised Set-up Operations Standard chart.


                                                                             36
Here is what was achieved ?

SOURCE: HIROTEC, www.hirotec.co.jp




                                             37
Word of Caution – On Sustainability

                          3                “Keep it simple, start
                                            in a small area and
                                               learn from it”
Changeover Time (Hours)




                          2




                          1




                          0
                                Original           Best                Later
                              changeover        changeover          changeover
                                 Time              Time                Time
                               (1999)             (2001)             (2003)
                                                                                 38
What lessons can you take from this?




Copyright Suiko-WCS International


                                          39
“What we think, or what we know, or what we
believe is, in the end, of little consequence. The
       only consequence is what we do.”

                                       - John Ruskin




                                                     40
Good Luck
http://www.linkedin.com/in/anandsubramaniam




                                              41

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Set up reduction

  • 1. Set-up Reduction / Quick Change Over / SMED Work smarter not harder, do things quicker & better and add value Anand Subramaniam
  • 2. “To the man who only has a hammer, everything he encounters begins to look like a nail.” - Abraham Maslow 2
  • 3. Highlights  Definition & Terms  Why, What, Where…How?  Implementation Roadmap 3
  • 5. Shigeo Shingo ..believed that Shingo explains why set- up reduction is critical to TPS – the principle behind the tool: any set-up “Provide the customer’s time can (internal and external be reduced customer) exact by requirement immediately 59/60ths! with perfect quality.” Productivity Press ISBN 0-915299-03-8 5
  • 6. SMED Vs. OTED (OTC)  SMED (Single Minute Exchange of Die)  Refers to a goal of reducing setup time to a single digit time or <10 minutes  OTED (OTC) One Touch Exchange of Die / One Touch Changeover  Refers to a goal of reducing setup time to <1 minute 6
  • 7. Set-up - Definition Ramp down period Ramp up period Set-up Time Output Production Loss Time 7
  • 8. Set-up - Definition Last First Good Good Piece Piece Total elapsed Time 8
  • 10. How is this reduction possible? 10
  • 11. Set-up Reduction - Goal Zero Set-up or Eliminate Set-up 11
  • 12. Set-up Reduction… Is NOT Is • A program to eliminate set- • A tool (like many) to reduce up people waste and excessive time • A panacea to overcome poor • A low-cost method to management or poor achieve increased capacity process layouts from existing equipment • A requirement to spend large • A process to reduce lot sizes capital investment to attain and improve product mix significant benefits • A cross-functional team approach to problem-solving 12
  • 13. Set-up Reduction – Bigger Picture  In order to reduce lead time  It is necessary to reduce lot size  Which in turn reduces work in process  To do this, you must reduce set-up time 13
  • 14. Set-up Reduction – Typical Application  Processes making a high variety of end items  Processes using high cost components (greater benefits of inventory reduction)  Capacity bottleneck operations  avoids purchase of new equipment  avoids overtime  better customer order fill  quicker response time 14
  • 15. Set-up Reduction – Traditional Practice Material movement Defects or missing Defective tooling, occurs after the equipment noticed fixtures, setup machine is turned when the machine instruments are off is running noticed, after the machine is turned on • Completed products • Setup tooling delivered are transferred to next after the changeover operation has begun • The operator notices that equipment is • Raw material is moved • Defective product missing tools etc after after the machine is identified after internal internal setup has stopped setup has begun begun 15
  • 16. Set-up Reduction - Benefits Trial processing Improved customer service eliminated & material levels waste reduced Less adjustment less errors Fewer shortages and Operating conditions stock-outs prepared in advance which helps to stabilise product quality Improved machine Benefits efficiency & level out production Increased scheduling flexibility / capacity Labour Increased utilised manf. process effectively On hand flexibility & inventory capacity Reduced Improved reduction overall Cost-of- cash flow Quality 16
  • 17. Set-up Reduction - Outcomes Happy Increased Increased Happy Improved Reduced capacity / flexibility custome customer lot sizes produc- through idle asset r usage tivity simplicity Improved Improve Set-up / tool and tool and change- product product Outcomes over time design eliminated design Improved Improve Improved mainten- Reduced mainten- Reduced Reduced material ance inventory ance lead time scrap flow and costs costs costs usage 17
  • 18. Set-up Reduction – Critical Success Factors Operators / set-up Elimination of waste people are the owners of the Small lot size process and its production results Training for operators and team 5S and Visual Control programs Flow Charting CSF current and Increase proposed flexibility in process equipment, processes Focus on and people equipment Simple Team up-time Cross- job work functional changes team 18
  • 19. Set-up Goals – Your Mandate  Target 50% Reduction First Time  Continuous Improvement Target 20% per year thereafter 19
  • 21. Set-up Reduction - Implementation Kaizen ‘SMED’ / ‘QCO’ Objective: Faster Changeovers (Set-Up Reduction) >50% Improvement Low cost 21
  • 22. Set-up Reduction – Implementation Start 6S, observe & document the current set-up time & process Identify & Standardise separate the new set- Internal and up procedure External tasks Observe and Eliminate and document the / or Improve new set-up each task process Externalise tasks that can be external and streamline internal task 22
  • 23. Set-up – Current Observation  Identify bottleneck process & the machine  Form cross functional Kaizen team (include shop floor)  Observe & video record the current set-up process  Capture start & end time for each time activity / category (use Pareto chart)  Identify counter measures that can be implemented with procedural changes to existing fixtures / tool / dies 23
  • 24. Set-up Reduction - Counter Measures  Review observation & video with the team for  Internal vs. External  Value Added Vs Non-Value Added  Normal vs. Abnormal  Types of Waste  Housekeeping (6 S & POUS)  Work flow (Spaghetti Chart)  Brainstorm ideas for improvement 24
  • 25. Set up Reduction - Types External Internal Executed Executed while the while the machine is machine is operating stopped Preparing tooling for the next set-up Removing dies and tooling 25
  • 26. Set-up – Time Typically Spent Prepare & perform functional checks, 30% Run first part & adjust, 50% Prepare machine for change over, 15% Actual change over, 5% 26
  • 27. Set-up Reduction - Checklist 27
  • 28. Set-up - Data Collection 28
  • 29. Set-up – Internal & External  Convert as much of the internal set up to the external set up  Eliminate or reduce the internal and external set up  Eliminate fine tuning and adjustment process. 29
  • 30. Set-up Reduction - Zero Reduce / Repeat Measure Separate Convert Eliminate till Zero External External External External and External Internal Internal Internal Internal Internal 30
  • 31. Set-up Reduction – Reduce / Eliminate Prepare (Dis)Mount Centre / Align Trial Run / Adj. (Re) Adjusting the equipment to Finding Taking tooling off (Re) Aligning run according to materials, jigs, / on the equipment to run specs gauges, etc equipment the next part Could take 40 ~ 60% of the set- Could take 20~ Could take 5 ~ Could take 10 ~ up process time 30% of the set- 15% of the set- 20% of the set- up process time up process time up process time Focusing here leads to set-up reduction times 31
  • 32. Set-up – Improvement Plan  SOP – SMED & 6S  Standardise tooling  Use quick fasteners  Document time savings  Standardise the external  SOP for machine shut set-up actions down or when running  Minor modification to the  Internal to external tooling existing fixtures attachment  Point of Use Storage  Visual & Audit Checklist 32
  • 33. Set-up Reduction - Ideas 33
  • 34. Set-up Reduction – Standards Standards are Defects or missing equipment noticed Defective tooling, fixtures, Material movement occurs when the machine is setup instruments are after the machine is running noticed, after the turned off machine is turned on standard: they are • Completed products are transferred to next operation • Raw material is moved after • Setup tooling delivered after the changeover has begun • The operator notices that equipment is missing tools etc after internal • Defective product NOT flexible the machine is stopped setup has begun identified after internal setup has begun 34
  • 36. Set-up Reduction - Repeat  Input  Last set-up reduction Kaizen (updated SOP, checklist, work instructions, trained team)  Process  Video tape the new set-up procedure and record the set-up time for each element  Generate ideas and implement the improvement  Output  Revised Set-up Operations Standard chart. 36
  • 37. Here is what was achieved ? SOURCE: HIROTEC, www.hirotec.co.jp 37
  • 38. Word of Caution – On Sustainability 3 “Keep it simple, start in a small area and learn from it” Changeover Time (Hours) 2 1 0 Original Best Later changeover changeover changeover Time Time Time (1999) (2001) (2003) 38
  • 39. What lessons can you take from this? Copyright Suiko-WCS International 39
  • 40. “What we think, or what we know, or what we believe is, in the end, of little consequence. The only consequence is what we do.” - John Ruskin 40