Quick Changeover: 2 Day Course Single-Minute Exchange of Die (SMED)

Introduction

Quick Changeover, sometimes referred to as Setup Reduction or SMED (Single-Minute Exchange of Die), eliminates or reduces non-value added activities in the setup and teardown processes of manufacturing, allowing companies to quickly and efficiently change from one product to another. Quick Changeover is a critical component of Lean Manufacturing, allowing companies to reduce batch sizes and shorten lead time, making it easier to meet customer demands for high-quality, low-cost products, delivered quickly and without the expense of excess inventory.

This workshop, with hands-on simulation, teaches the fundamental principles of set-up reduction. It defines set-up, and participants will discuss reasons and barriers to reducing set-up time. The course follows the principles first expressed by Dr. Shigeo Shingo and his work on Single Minute Exchange of Die (SMED). Participants learn the standard methodology in applying SMED. The techniques covered demonstrate how to reduce changeover time from hours to minutes and even seconds. This group training exercise is designed to precede a Quick Changeover implementation, or Kaizen event.

• Understand how quick changeover/setup reduction supports lean manufacturing
• Learn key concepts and principles related to Quick Changeover/setup reduction
• Develop skills required to apply Quick Changeover using a disciplined, visual process of documentation and improvement
• Experience a team approach to quick changeover/setup reduction
• Recognize how quick changeover/setup reduction can be applied to support functions throughout the value chain

1. Introduction

• The History of SMED
• Types of Maintenance
• What is SMED?
• Benefits of SMED
• The roles of SMED
• Waste Management
• Setup Practices
• Traditional /Strategic Setup Approach

2. Single Minute Exchange of Die: Overview

• Definition of Changeover Time
• Traditional Changeover and the Wastes of Lean
• Benefits of Shortening Changeover Time
• What is High Speed Die cutting?
• Identify changeover improvement priorities

3. What are the Essential Disciplines of SMED?

• Teamwork
• Standardization, Benchmarking & Simplification
• The Procedural Training System
• Key Result Analysis System
• Information Management System
• Inventory Management System
• Just-In-Time Organization
• Time Management System
• Parallel Processing
• One Touch Tooling
• Logout/Tag Out (LOTO)
• The use of tools and importance of correct tools
• Mistake Proofing
• System Maintenance

4. The 4 conceptual stages of SMED

• Preliminary stage
• Identify internal vs. external changeover tasks
• Analyze each task’s real purpose and function
• Focus on no/low cost solutions
• Aim to eliminate changeover time

Stage 1. Separating internal and external setup

• Develop and implement changeover checklists.
• Perform function checks on parts and tools.
• Reduce transportation of tools, parts, and materials.
• SMED: Separate Internal and External Setup
• Develop specific checklists for every piece of equipment and major process.
• Are all of the changeover materials in good working order?
• Have all materials been checked far enough in advance to allow time for repairs?
• Reduce non-value added movement of changeover parts, tools, and materials
• Transport changeover materials before the machine shuts down
• Focus on no/low cost solutions

Stage 2. Converting internal setup to external setup

• Focus on functions such as dimensioning, securing, gripping, and centering
• Replace the fewest possible parts by changing the way we perform the function
• Design and build standard-sized, removable plates or frames
• Externally attach and adjust die/parts
• Eliminate internal adjustments to individual parts during changeover

 Stage 3. Streamlining all aspects of the setup process

• Divide changeover tasks between two or more people.
• Maintain detailed changeover procedures.
• Use visual marks to indicate correct settings
• Create “quick set” mechanisms to handle different functions
• Install fixed stops to indicate where a part should be positioned

5. Implementing Single Minute Exchange of Die

• Staying on the Course
• SMED Implementation Planning
• Implementation Team
• Implementation Plan
• Communication Plan
• Training Plan
• Implement Quick Changeover improvements
• Monitor and document results
• Develop a plan to standardize improvements

6.     Improve Occupational Health and Safety (OHS)

• Identify hazards to self or others in all steps/actions
• Determine risks from each hazard
• Identify actions which may be performed in a more ergonomic manner
• Recommend changes to improve OHS