This document provides an overview of Single Minute Exchange of Die (SMED), a methodology developed by Shigeo Shingo to reduce changeover times in manufacturing. SMED involves separating changeover tasks into internal and external activities, then converting internal tasks to external to reduce downtime. Benefits of SMED include lower costs, improved flexibility and responsiveness. The document outlines SMED's history and implementation techniques, and provides examples of how Formula 1 pit stops, cruise ships, and fire stations effectively use SMED principles to perform rapid changeovers.

1. Single Minute Exchange of Die
Reema Mangtani PG14063
Simran Jain PG14074
Deepak Nadar PG14094
Frahvak Dumasia PG14095
Chaitra Mhatre PG14101
Gaurav Sonwani PG14117
Team Members

2. Introduction
• Term used to represent the Single Minute Exchange of Die or setup time that can be
counted in a single digit of minutes
• Successful implementation of SMED and quick changeover is the key to a competitive
advantage for any manufacturer
• Effective SMED programs identify and separate the changeover process into key
operations: Internal and External

3. How Can SMED Help Any Organization
• Reducing downtime associated with the changeover process
• Reducing the waste created during startup
• Accelerate progress: Focus on people first

4. History
Developed by Shigeo Shingo
( in the late 1950’s and early
1960’s) chief engineer of
Toyota
• Shigeo Shingo was a Japanese industrial engineer and
father of SMED
• He developed SMED while working for Toyo
Industries in 1950
• He sought to eliminate bottlenecks by looking
at changeover operations on large presses
• Shingo helped improve Mitsubishi Heavy Industries productivity by 40%.
• In 1969, Shingo continued to perfect the SMED system at Toyota Motor Corporation’s
main plant
Changeover
time size Process time
per item
Operation
time Ratio
8 hours 100 1 min 5.8 min 480%
8 hours 1,000 1 min 1.48 min 48%
8 hours 10,000 1 min 1.048 min 4.8%

5. Transformation
How long
does it take to
change the
tire???

6. Implementation/Working of SMED
• Step One – Identify Pilot Area
• Step Two – Identify Elements
• Step Three – Separate External Elements
• Step Four – Convert Internal Elements to External
• Step Five – Streamline Remaining Elements

7. Implementation Techniques Of SMED
1. Separate internal from external setup operations.
2. Convert internal to external set-up
3. Standardize
4. Use clamps and “one-touch” fasteners
5. Use intermediate jigs
6. Adopt parallel operations
7. Eliminate adjustments
8. Mechanization: This should be used as the last resort

8. Benefits of SMED
• Lower manufacturing cost
• Smaller lot sizes
• Improved responsiveness to customer demand
• Lower inventory levels
• Smoother startups

9. Practical Use of SMED
DID YOU KNOW?
 10 min/day of downtime is more than one week per year of lost
production
 Surely you can save more than 10 minutes each day
 What is a week’s production worth?

10. Some effective techniques:
 Visual Controls: Effective communication in a merchandising department
 Order status
 Merchant responsible
 Stage at which the order is
Purpose:
 To make daily follow-up checklists
 For the dependant departments to know the process status and change their plan
accordingly
Practical Use of SMED

11. Checklist:
 Questionnaire placed near the machine to be checked before each setup process
Check panel :
 Next to the machine to make available all the tools
at the required time
Parts and tools transportation improvements:
 Transportation from the warehouse to the work area
carried out before the exchange begins
Endless material method:
 In a rolling mill or on packing machines
End of a reel is welded or tied to the beginning of the
following one
Practical Use of SMED

12. Tools duplication :
 It is possible to prepare the next two containers
 Eliminates the need of removing and placing the containers again
Remote Control:
 A worker had to go from the third floor to the basement every time a valve
needed to be turned on or off
 Replaced the manual valve with a remote-controlled electric valve
 Effectively gave the plant 4 weeks of additional production time per year, at a cost
of less than $500
Practical Use of SMED

13.  Formula 1 Pit Stop
 Changing tyres and refuelling goes lightning fast
Practical Use of SMED

14. Cruise Ship
 Dock and disembark some 3,000 passengers, luggage and take on
3,000 new ones
 Restock tons of food and supplies
 Perform necessary maintenance to the ship
 Sail again all in the course of a few hours
 Equipped with specially designed devices and a very well trained
crew
Practical Use of SMED

15. Stored with a purpose
Firemen in the fire station sliding down fire poles
Set up of pants and boots to slide in quickly
Practical Use of SMED
Fire Fighters

16. Conclusion
• SMED is an ideal tool which can
be used to reduce the changeover
time/set-up time in many
industries
• It increases the flexibility of the
company to produce the right
number of products
Single-Minute Exchange of … Cocktail?!

17. Weblography
• http://en.wikipedia.org/wiki/Single-Minute_Exchange_of_Die
• http://www.vorne.com/learning-center/smed-quick-changeover.htm
• http://www.leanproduction.com/smed.html
• http://www.makigami.info/cms/smed
• http://www.processexcellencenetwork.com/business-process-management-
bpm/articles/single-minute-exchange-of-dies-smed/