PPT ON SINGLE MINUTE EXCHANGE OF DIES (SMED)

SMED (Single-Minute Exchange of Dies) is a system for reducing equipment changeover time in manufacturing. The essence of the SMED system is to convert as many changeover steps as possible to “external” (performed while the equipment is running), and to simplify and streamline the remaining steps.
�SMED – It is a method of reducing time in total equipment changeover.
SMED is the term used to represent the Single Minute Exchange of Die or setup time that can be counted in a single digit of minutes. Its goal is to reduce the setup time from hours down to less than 10 minutes
It provides a rapid and efficient way of converting a manufacturing process from running the current product to running the next product.
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1. Single Minute Exchange of Dies

2. Introduction

SMED (Single-Minute Exchange of Dies) is a system for reducing

equipment changeover time in manufacturing. The essence of the SMED
system is to convert as many changeover steps as possible to “external”
(performed while the equipment is running), and to simplify and
streamline the remaining steps.

3. Definition
+ SMED - Single-Minute Exchange of Dies is a method of reducing time in
total equipment changeover.

+ SMED is the term used to represent the Single Minute Exchange of Die or
setup time that can be counted in a single digit of minutes.

+ SMED provides a rapid and efficient way of converting a manufacturing
process from running the current product to running the next product.

4. History

* The process was developed by Dr. Shigeo Shingo in Japan during
the sixties and early seventies at Toyota.

+ Dr. Shingo was given the challenge of increasing production
capacity without purchasing new equipment.

«His research at first was mostly spent observing machines in
action and trying to understand how to make them run faster.

5. Why SMED?

«To eliminate the wastes that result from “Uncontrolled” processes
increasing inventories and lead times.

+ To gain Control on equipment material and inventory.

«To standardize improvements for maintenance of critical setup
parameter.

6. Principle

The basic principles of SMED are:

+ Identify internal versus external changeover tasks.
+ Analyze each task's real purpose and function.

+ Focus on no/low cost solutions.

+ Aim to eliminate changeover time.

7. Different Stages

+ Stage 1. Ensure that external setup actions are performed while the
machine is still running.

+ Stage 2. Separate external and internal setup actions, to ensure that the all
parts functioning well and implement efficient ways of transporting the die
and other parts.

+ Stage 3. Convert internal setup actions to external.

+ Stage 4. Improve all setup actions.

8. Implementation Steps

There are different steps for implementing SMED
1. Develop and complete the external set-up checklist.

+ Create a list of molds/dies, tools, fixtures, materials and gauges.
* Process information and storage locations.

2. Develop and complete set-up reduction observation forms.
* Observe the whole process.
+ Identify and list each step.
« Classify into internal or external activity.

9. Implementation Steps

3. Convert internal to external set-up.

4. Standardize: In this step, the size changeover tools are
examined and replaced with standard sizes.

5. Adopt parallel operations.

6. Eliminate adjustments

10. External & Internal
Activities

External Setup activities
* Fetching new tooling
* Returning the old tooling
* Finding tools for the setup
* Finding correct paperwork
+ Fetching raw materials

11. External & Internal
Activities

Internal Setup activities
* Removal of guarding from equipment
* Removal of the old tool
* Placing the new tool
* Connecting services such as air to new tool
¢ Clearing hoppers / material feeders

12. Advantages

Some of the advantages of SMED are:
* Increase machine availability time.
* Short changeover time.
* More efficient output through machines.
* Increased responsiveness to customer complainants.

13. Limitations

Limitations of using SMED:

* Potential reduction in efficiency when adding new member who
doesn’t fully understand role.

¢ Costly when adding too many members to changeover process.

« Potential limitation of work space when adding too many member.

14. Conclusion

+SMED is an ideal tool which can be used to reduce the changeover
time/set-up time in many industries (including manufacturing, logistics,
and service).

« SMED increases the flexibility of the company to produce the right
number of products at the right time and eliminates or minimizes
bottlenecks to increase flow.

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