singlwe minute exchange of diein lean manufacturing

lean manufacturing

1. QUICK CHANGE OVER
Single
Minute
Exchange of
Dies

2. C
h
a
n
g
e
o
v e
r tim
e
Traditional setup
Single Minutes Exchange of Dies
SMED Process Steps
Ideas for Improvement
QUICK
CHANGE
OVER
CONTENTS

3. INTRODUCTION
Mold Change
Colour Change
Mold change Inspect/Adjust
Setup
Time
1
st
Piece Time
(good or bad)
1
st
Good
Piece Time
0
Last good part
The time elapsed between
when the last good piece of
product A comes off
and the first good piece of
product B starts.
Changeover time:
Definition
Available time
Available operating time
Actual operating time
Effective
Operating time
Breakdowns
Setup/
adjustment
Idling/minor
stoppages
Speed
Defects in
process
rework
Start-up
losses
EQUIPMENT SIX BIG LOSSES

4. INTRODUCTION
History : Land costs in Japan were very
high, therefore it was not feasible to store
large inventories of vehicles
Developed by Shigeo Shingo
( in the late 1950’s and early 1960’s)
chief engineer of Toyota
Reduces the waste of inventory by creating shorter production runs
that better align with customer demand
“A rapid and efficient way of converting a
process from running the current product
to running the next product “
QUICK
CHANGE OVERS

5. QUICK CHANGEOVER IN LEAN

6. TRANSFORMATION
How long
does it take
to change
the tire???

7. 6 “Traditional” Setup Steps

8. INTRODUCTION
SMED:
Single Minute Exchange of Die
Concept that says all setups
should and can take less than
10 minutes
OTED:
One Touch Exchange of Die
Concept that says all setups
should and can take less than
100 seconds!
What is “World-Class”
in Quick Changeovers?

9. The SMED Process
Reduce inventory
Reduce batch sizes
Reduce changeover time
Reduce impact on equipment
utilization
Improve quality after changeover
Improve repeatability
Improve throughput
Improve flexibility
Observe
and record
Separate
internal and
external
activities.
Convert
internal
activities to
external
activities
Streamline all
activities
Document
internal
and
external
procedures

10. THE SMED PROCESS
1. OBSERVE AND RECORD
We should always:
Notify the party to be observed ahead of time
Explain why we are conducting an observation
We’re observing the activity not the person
What we are trying to accomplish
Explain the possible benefits for them and the
company
Review the observation with the individual
Coaching
Clarification
REMEMBER!!!
These activities are not
conducted for the purpose of
eliminating jobs or reducing
people!
 Identify internal and external elements,
 waste/lost time,
 variances from the standard process

11. THE SMED PROCESS
2. SEPARATE INTERNAL AND EXTERNAL ACTIVITIES
All Setup All Setup ActivitiesActivities RunRun
III I
EE EE EEEE RunRun
ExternalsExternals
Internals
RunRun
ExternalsExternals
Post-setup
externals
Internal elements:
operations that must be performed while the machine/process is stopped
External elements:
operations that can be performed while the machine/process is running

12. THE SMED PROCESS
3. CONVERT INTERNALS TO EXTERNALS ACTIVITIES
InternalsExternalsExternals RunRun
InternalsExternalsExternals RunRun
Internals
ExternalsExternals RunRun
ExternalsExternals Internals RunRun
ExternalsExternals
Internals
RunRun
Eliminate adjustment

13. THE SMED PROCESS
How to convert externals
to internals ?
Eliminate search-and-find work
Arrange tools & materials beforehand
Complete prep work before starting changeover
Standardize settings
Make visual marks vs. trial and error adjustments
Eliminate trial runs
Postpone “put away” work

14. THE SMED PROCESS
4. STREAMLINE ALL ACTIVITIES
Machine
running
Machine
running
Last good piece of
product A
First good piece of
product B
Total setup
Internal and external elements
Internal
elements
Machine
running
Machine
running
Last good piece of
product A
First good piece of
product B
Total setup
External elements External elements
Streamlined
internal
elements
Machine
running
Machine
running
Last good piece of
product A
First good piece of
product B
Total
setup
Streamlined
External
elements
Streamlined
External
elements
BEFORE
AFTER
CHANGE
OVER
STREAM
LINE

15. STREAMLINE
INTERNAL PROCESS
Create Parallel steps – completed
at the same time
Reduce complexity and eliminate
waste
Use functional fixtures and jigs
•one motion fasteners
•levered or one-turn fasteners
•interlocking wedge or slot
Eliminate adjustments
•use angle and flat
•use preset pins, guides, notches etc.
Eliminate need to leave the machine
•Use POUS and water spider
STREAMLINE
EXTERNAL PROCESS
Adopt functional standards
Visual factory locations for
tools
Color coding
Standard set ups
Checklists
THE SMED PROCESS
ADOPT
QUICK DIE
CHANGEOVER
( QDC)
HARDWARE

16. THE SMED PROCESS
•Make adjustments, as needed
•Re-test, if necessary
5. DOCUMENT INTERNAL & EXTERNAL PROCEDURES

17. THE SMED PROCESS
•Make adjustments, as needed
•Re-test, if necessary
5. DOCUMENT INTERNAL & EXTERNAL PROCEDURES

18. THE SMED PROCESS
•Make adjustments, as needed
•Re-test, if necessary
5. DOCUMENT INTERNAL & EXTERNAL PROCEDURES

19. WHEN SHOULD YOU AUTOMATE??
Criterion 1:
The operation has
already been
dramatically simplified
Criterion 2:
Begin with semi
automation to achieve
80% benefit at 20%
cost
Criterion 3:
The automation is
cost-effective

20. IDEAS FOR IMPROVEMENT
Setup sheet
Prints
Special instructions
Gauges
Set blocks
Stop gauges
Special tools
SET-UP TOOL CARTS

21. IDEAS FOR IMPROVEMENT
SET-UP
DIE CARTS
Documentation
Tools
Rollers
Turntable

22. IDEAS FOR IMPROVEMENT
Slot address labels
Slot
address
Model
Slide
value
Part Line #Cover
Block
gauge #
ORGANIZE & STORE IN
PROXIMITY

23. IDEAS FOR IMPROVEMENT
Clamping height
Cut away

here
Add

spacers

here
STANDARDIZE CLAMPING HEIGHT

24. IDEAS FOR IMPROVEMENT
Spring
plate
Adjusting
pin
Interior space
(inaccessible)
Adjusting
wedge
Adjusting
screw
Better
Linear gauge
& pointer
Dial gauge
Better Still

25. Die
4-piece
clamp
Spring
Die
heights
vary
Bolster
Plate
Socket wrench
removes screw
Socket head cap screw4
3
1
2
IDEAS FOR IMPROVEMENT
Die
L clamp
Spring
Standardize
clamp
heights on
dies
Bolster
Plate
Nut is not removed
for setup!
BEFORE
AFTER
Streamlined 1-Piece Clamp

26. Before
After
Mold
Stopper
Cam
lock
Eliminate boltsEliminate bolts
IDEAS FOR IMPROVEMENT
QUICK RELEASE CAM LOCK
TOGGLE LOCK
DOWN CLAMP

27. IDEAS FOR IMPROVEMENT
Die
Before
Bolster
After
Bolster
DieSlot
Top view
Side view
1. Lift
2. Tighten
Bolt & Slot
Hinged
Bolt
Centering
Jig