The document discusses lean manufacturing techniques including Single Minutes Exchange of Dies (SMED) and preventative maintenance. SMED aims to reduce changeover times to less than 10 minutes by separating internal and external changeover steps. It was developed in the 1950s-60s by Shigeo Shingo at Toyota to reduce bottlenecks. Preventative maintenance involves scheduled inspections and minor repairs to reduce unexpected breakdowns and increase equipment efficiency. It provides benefits like reducing downtime, costs, and safety issues compared to breakdown-based maintenance.

1. Raghavendra Paradkar
Murtaza Dalal
Uzair Patel
Shamsher Pathan
Neha Jaiswal

5. MEANING OF A SET UP TIME
 Study blueprints
 Get tools and gauges
 Select and secure Fixture
 Mounting, adjustments, feeder
 QA inspection, pilot run
 Count the jobs produced
 Remove tools, mountings, fixtures
 Cleaning

6. LEAN MANUFACTURING
 Reducing waste
 Increasing productivity
 Innovative practices
 Inculcating good management systems
 Continuous improvement

7. LM Techniques
 5S System
 Visual Control
 SOPs
 JIT
 KANBAN System
 Cellular Layout
 Value Stream Mapping
 Poka Yoke
 Single Minutes Exchange of Dies (SMED):
 TPM
 Kaizen Blitz

10. SMED
 “Applying Ingenious methods, to bring set up time to
less than 10 minutes”.
 One-Touch Exchange of Die>>changeovers less
than 100 seconds

11. HISTORY
 The concept arose in the late 1950s -1960s
 Shigeo Shingo >> Toyota
 Bottlenecks at car body-moulding presses
 Long tool changeover times
 Drove up production lot sizes
 Direct impact on Productivity

12. OBSERVATIONS
 Most difficult tools to change >>dies on the transfer-
stamping machines that produce vehicle bodies
 The existing process took from twelve hours to
almost three days to complete

13. IMPLEMENTATIONS
 Place precision measurement devices on the transfer
stamping machines
 Record the necessary measurements for each model's die
 Scheduling the die changes in a standard sequence
 Toyota cut the change-over time to less than 10 minutes
per die

14. BENEFITS OF SMED
 Reduce batch size
 Reduce lead time
 Reduce inventory
 Reduce scrap
 Increase efficiency
 Increase flexibility

16. SMED in Toyota factory

18. MAINTENANCE

19. MAINTENANCE DEFINITION
Maintenance is a set of organised activities
 “
that are carried out in order to keep an item in
its best operational condition with minimum
cost acquired”.

20. cont….
 The combination of all technical and administrative
actions.
 Including supervision actions, intended to retain an item
in, or restore it to, a state in which it can perform a
required function
 Repair or replacement activities

21. PLANT
Optimising
Resources
Utilisation
Maximising
Production
Minimising
Energy Usage
Optimising
Useful Life of
Equipment
Providing
Budgetary
Control
M
A
I
N
T
E
N
A
N
C
E
Reduce
Breakdowns
Reduce
Downtime
Improving Equipment
Efficiency
Improving
Inventory Control

22. TYPES

Run to Failure Maintenance (RTF)

Preventive Maintenance (PM)

Corrective Maintenance (CM)

Improvement Maintenance (IM)

Predictive Maintenance (PDM)

23. BREAKDOWN MAINTENANCE
 Repairs are made after the equipment is failed
 Machine can not perform its normal function anymore
 Bring this machine to at least its minimum acceptable
condition
 It is the oldest type of maintenance

24. WHERE TO USE
 The failure of a component in a system is
unpredictable.
 The cost of maintenance is lower than other activities
of other types of maintenance.
 Financial justification for scheduling are not felt

25. DISADVANTAGES
 Poor and hurried maintenance
 Safety issues for both workers and machines
 Delay in production & reduces output
 Direct loss of profit

26. Preventive Maintenance (PM)
“Prevention is better than cure”
“Stitch-in-time”
 Locates weak spots of machinery and equipments.
 Periodic/scheduled inspections
 Minor repairs to reduce the danger of unanticipated breakdowns.

27. FACTORS OF PM
 Adequate staff in the dept.
 Qualified and skills (ITI)
 The right choice equipment.
 The support from management
 Planning and scheduling of PM programme.
 The ability to properly apply the PM programme

28. Classification of PM

Routine maintenance

Running maintenance

Opportunity maintenance

Window maintenance

Shutdown preventive maintenance

29. ADVANTAGES
• Reduces break down & down time
• Less odd-time repair and reduces over time of crews
• Greater safety of workers
• Lower maintenance and repair costs
• Less stand-by equipments and spare parts
• Better product quality and fewer reworks and scraps
• Increases plant life
• Increases chances to get production incentive bonus